In collaboration with University of Pisa spin-off SkyBox Engineering, Roboze is applying their 3D printing expertise to drone parts, reducing component weights and improve efficiency. SkyBox applied FFF printing systems to produce carbon fiber-filled polyamide components. Aside from the better shape and the weight reduction, they were also able to reduce production times significantly.
As a company, SkyBox Engineering formed out of Aerospace Engineering Department of Pisa University. Researching and testing new design methodologies is basically in its DNA and is standard mode of operation, according to the company. Roboze’s technology helped them develop new housings for drone that that were 25% lighter and incorporated dampers helps to negate the high frequency vibrations caused by motors.
A large part of this comes down to more robust design and replacing certain aluminum parts with Carbon fiber PA. Roboze reiterates this view, considering their material to be as “Strong as Metal, Light as Polymer”. As a result, it offers an ideal non-metal alternative for electronics components that need to be nimble and strong.
“The necessity of using 3D printing results from the nature of our projects”, comments Vincenzo Binante, Engineer at SkyBox. “The main goal is the reduction of weights and encumbrances of the parts that are positioned on drones and aero models, getting advantage of the possibility to build functional parts with even complex shape” We chose Roboze for the quality of the material and the chance to test different printing processes. Moreover, Roboze’s solution allows [us] to have a protected and controlled build plate with a good precision and to get confident with the printer extremely quickly”.
Lightweight Drone Printing
While weight reduction was the main goal, there were additional benefits to opting for 3D printed designs. The the team could also modify the various parts very quickly and prototype them almost instantly. This allowed the researchers to reduce production times by about 20 percent.
“The Roboze solution permitted to definitely speed up the prototyping process, as allows a more direct transfer from the CAD model to the realization of the part, compared to the traditional manufacturing methods,” states Binante.
These improvements were also thanks to Roboze’s Beltless system, which allowed SkyBox to improve the repeatability of their 3D printed parts. This technology uses racks and helical pinions consisting of tempered steel to achieve precise 25-micron mechanical tolerances. Another crucial tool for these design improvements was the Carbon PA, presenting a tensile strength of 138MPa.
The design will allow for the drone to fly smoothly and operate with minimal vibrational interference. It also provides a use-case for how polymers can replace certain metal components, providing lightweight alternatives.
Featured image courtesy of Roboze.
