Superlight, Jet Powered and 3D Printed – A Game Changing UAV

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Aviation company Aurora Flight Sciences and 3D printer manufacturer Stratasys may have changed the Unmanned Aerial Vehicle (UAV) field for ever with a new drone.

The new drone is breaking all the records on the books. It is the biggest and most complex 3D-printed vehicle to be created, claim the companies. On top of that, it is one of the lightest UAVs for its size. With a wingspan of over 2.5 meters, it weighs just under 15 kilograms and can reach some impressive speeds – over 240 kilometers an hour.

One of the most awe-inspiring things about the new drone isn’t even the machine itself. It’s how quickly it was made.

“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,” says Dan Campbell, Aerospace Research Engineer at Aurora Flight Sciences. “Overall, the technology saw us cut the design and build time of the aircraft by 50%.”

The UAV’s light weight and strength were made possible by Stratasys’ patented Fused Deposition Modeling (FDM) technology, which uses ULTEM production-grade thermoplastic. The material meets the flame, smoke and toxicity requirements set by the US Federal Aviation Administration, and is acknowledged as ideal for airplane components due to its thermal, chemical and mechanical qualities.

Owing to its extremely light weight, the UAV will use far less fuel than comparable drones. The manufacturing technique developed during the joint project should prove to be a great cost-saving advancement, as well. 3D printing to exact specifications will reduce waste and recycling costs.