Sheffield University produces 3D printed UAV

Low production costs could lead to the printing of 3D unmanned aircraft that could be disposable and sent on one-way flights

Engineers at the University of Sheffield have printed a 1.5m-wide prototype unmanned aerial vehicle (UAV) as part of a project looking at 3D printing of complex designs.

The UAV is made up of nine thermoplastic parts, weighing less than 2kg, that can be snapped together. Engineers are evaluating the potential of nylon as a printing material that would make the UAV 60% stronger with no increase in weight.

The researchers said the polymer craft could form the basis of cheap and potentially disposable UAVs that could be built and deployed in remote situations potentially within as little as 24 hours.

New 3D printing techniques, such as the fused deposition modelling used to make the UAV at Sheffield, could soon be used in the creation of products without the need for complex and expensive tooling and the time required in traditional manufacturing, the researchers explained.

Dr Garth Nicholson, who led the project, said: “Following successful flight testing, we are working to incorporate blended winglets and twin ducted fan propulsion. We are also investigating full on-board data logging of flight parameters, autonomous operation by GPS, and control by surface morphing technology. Concepts for novel ducted fan designs are also being investigated."

The AMRC is part of the High Value Manufacturing Catapult, a consortium of seven manufacturing and process research centres backed by the Technology Strategy Board. It is also supported by the European Regional Development Fund.

Find out more about the UAV here.