UAV

3D printing and additive manufacturing solutions provider Stratasys has partnered with Aurora Flight Sciences to produce the world’s first jet powered 3D printed unmanned aerial vehicle (UAV).

The product, which was put on display for the first time at the ongoing Dubai Airshow, features a 3m (9ft) wingspan and 15kg weight.

Both companies said the new aircraft will be the largest, fastest and most complex 3D printed UAV in the world that can achieve more than 150mph.

Stratasys said it used lightweight materials to build the aircraft, which is 80% made with 3D printed materials, including metal, nylon and UV-resistant thermoplastic.

According to the company, the materials helped cut the UAV design and manufacturing time by 50%.

Aurora Flight Sciences aerospace research engineer Dan Campbell said: "A primary goal for us was to show the aerospace industry just how quickly you can go from designing to building to flying a 3D printed jet-powered aircraft.

"To the best of our knowledge, this is the largest, fastest, and most complex 3D printed UAV ever produced."

"To the best of our knowledge, this is the largest, fastest, and most complex 3D printed UAV ever produced."

The project uses Stratasys’ flagship fused deposition modelling (FDM) 3D printing technology.

Stratasys Vertical Solutions aerospace and defence senior business development manager Scott Sevcik said: "This meant using different 3D printing materials and technologies together on one aircraft to maximise the benefits of additive manufacturing and 3D print both lightweight and capable structural components.

"Whether by air, water or on land, lightweight vehicles use less fuel. This enables companies to lower operational costs, as well as reduce environmental impact.

"In addition, using only the exact material needed for production is expected to reduce acquisition cost by eliminating waste and reducing scrap and recycling costs."

Image: Making its global debut at the Dubai Airshow, Aurora Flight Sciences’ high-speed UAV is 80% 3D printed with Stratasys additive manufacturing solutions. Photo: courtesy of Stratasys.