Researchers at Nanyang Technological University, Singapore (NTU Singapore) have collaborated with Stratasys’ Asia Pacific subsidiary to create a 3D-printed ready-to-fly drone with embedded electronics using aerospace-grade material.

The researchers have integrated the electronics in the drone during the 3D printing process, which uses a high-strength, lightweight-fused deposition modelling (FDM) material certified for commercial aircraft known as Stratasys ULTEM 9085.

"One of the toughest challenges was to find electronic components that could theoretically survive the high-temperature printing process."

A quadcopter with four rotors, the newly developed drone has been designed, 3D-printed and flown by an NTU PhD candidate and NTU's Singapore Centre for 3D Printing (SC3DP) researcher Phillip Keane.

Developed within 14 hours, the drone can support more than 60kg in weight suspended from its structure.

Keane said: "One of the toughest challenges was to find electronic components that could theoretically survive the high-temperature printing process, we had to add some heat-proofing modifications to the components to ensure they could last.

“This involved adding new components to the printed circuit boards and also designing custom housings.

"The housings, which were pre-printed in ULTEM 9085, also provide a flat surface for the 3D printer to continue printing over them. I also had to deal with tight time constraints as some of the components could not survive in the heat for more than 20 minutes."

Keane is also working on to develop the next version of the drone that will include enhanced durability, lighter weight and improved flight dynamics.

With a workforce of 2,700 people, Stratasys currently has 1,200 granted or pending 3D printing or additive manufacturing patents.

Image: Phillip Keane from Nanyang Technological University, Singapore examining his Stratasys 3D printed quadcopter. Photo: courtesy of Stratasys.