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Bridgeport Research Duo Create and Analyze 3D Printed Frame for Quadrotor Drone

Quadrotor frame assembly in exploded view.

Unmanned Aerial Vehicles (UAVs), also known as drones, are agile and resilient enough to be piloted, and monitored, from remote distances. With four flying dimensions and six degrees of freedom for pitch, roll, space, and yaw, drones can be used for a wide variety of applications, such as farming, documenting 3D information about historic archaeological sites, photography, military and defense, acting as first responders during natural disasters and rescue operations, and 3D printing.

Multirotor drones have multiple fixed wings and have a high level of maneuverability, and are classified further based on factors like position, orientation, and number of rotors. A pair of researchers from the University of Bridgeport recently published a paper, titled “Design and Analysis of 3D Printed Quadrotor Frame,” detailing their work using 3D printing to create the frame for a quadrotor drone.

3D printed drone assembly bottom view

The abstract reads, “This research emphasizes more on 3D printing a quadrotor with ‘X’ shaped frame. We built a CAD model of drone frame using SOLIDWORKS, following that; we performed three types of finite analysis 1. Static structural, 2. Impact analysis, and 3. Modal analysis. The drone frame is simulated and analysed under various boundary conditions such as lift, drag, and thrust till the optimized results of minimum displacement, a factor of safety is achieved. We printed the frame of drone on PRUSA I3 Mk3 3D printer by using ABS-PC and carbon fiberglass materials as the filament.”

The researchers designed a CAD model of their X-framed drone in SOLIDWORKS using multiple constraints, including:

  • length of the propeller, which determines the length of an arm
  • motor rotor diameter and electronic speed controller width, which contribute to determining a drone’s arm width

Highlighted surface area is the fuselage

They designed the arms of the drone to translate force away from the fuselage, which helps electronic components maintain minimal damage if the drone has an accident or fails. The fuselage of a drone is “the eye” of its electronic components, like the receiver, power distribution board, and flight controller, and the duo designed a housing to protect the fuselage’s components in the event of a crash.

The dimensions of their drone frame, which was 3D printed on a PRUSA I3 Mk3 3D printer out of carbon fiberglass and ABS-PC, are 175.14 x 171.42 x 48.75 x 226 mm.

The researchers explained, “To perform FE analysis, the forces acting on a frame are determined, which are 1.The Weight of the frame and all the electronic components on it normal to the ground, 2. Lift force direction is a resultant between thrust and vertical take-off, towards the direction of motion, 3. Thrust generated by the propeller and motor towards the direction of motion and 4. Drag force acting in opposite direction of motion.”

Strain deformation

The researchers manually calculated and applied the forces acting on the 3D printed frame during simulation, which resulted in three plots: Von Mises stress, displacement, and strain deformation. They were able to run a sequences of cycles in SOLIDWORKS where the drone crash-landed, and gained simulation results by compiling all of the collected data. Additionally, they also completed a static structural analysis – a phenomenon called plasticity – by considering a non-linear analysis based on the materials used to make the frame and the rate of deformation, and completed a modal analysis of the 3D printed frame in order to measure the dynamic excitation caused by vibrating motors.

“A 3D printed quadrotor frame with safety factor 2.5 is attained and various finite element analysis performed on the frame are distinctly mentioned and plotted in the figures. Further, we can 3D print a 3- axis gimbal and attach it to our quadcopter for aerial photography. Also, we can upgrade them by attaching few thermal imaging sensors and gas sensors to measure radiation and air pollution at certain heights,” the researchers concluded. “This shows the main advantage of the 3D printed quadcopters and makes them stand distinct to the market-ready drones. We can customize them to make them work in any environment just by changing the printing filaments.”

3D printed drone assembly isometric view.

Co-authors of the paper are Sai Mallikarjun Parandha and Zheng Li.

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Titomic Shares News About 3D Printing Executives and $1.8 Million MoU to Make 3D Printed Soldier Systems

Australian metal 3D printing company Titomic, known for its innovative Titomic Kinetic Fusion (TKF) process, has plenty of big news to share this week. First, CEO Gilbert Michaca, who was responsible for implementing a series of governance and operational structures to support Titomic’s next growth phase, has resigned from the company.

“I have enjoyed my time with Titomic and the additive manufacturing sector, but I am moving to pursue other commercial opportunities more aligned with my interests,” said Michaca. “I look forward to witnessing Titomic’s growth and prosperity in the future.”

Jeffrey Lang

In addition to Michaca’s resignation, Titomic announced that its founder and former Interim CEO Jeffrey Lang, who led the company through its IPO, and the establishment of its cold spray facility in Melbourne, has now been appointed as the Managing Director, effective immediately.

“Following our whirlwind IPO and unprecedented growth phase, the Titomic team has delivered a lot in a very short period of time,” said Titomic Chairman Philip Vafiadis. “With Jeff stepping into his new role as the Company’s Managing Director we are excited that his significant knowledge and networks across industry sectors, his deep understanding of the technology, his experience, his passion and his understanding of investor needs bodes well for future growth and shareholder value.”

Moving on from news about its executives, Titomic has just signed a $1.8 million, year-long MoU with fellow Australian company TAUV Proprietary Limited (TAUV), which integrates electronic technologies into solider protection for the purposes of improving safety and performance. Together, the two will begin an exclusive defense program for Titomic to manufacture soldier systems, unmanned aerial vehicles (UAV), and soldier sensors for TAUV.

Recently, TAUV completed a successful launch of the first ruggedized titanium tactical UAV at Land Forces 2018, which was manufactured by Titomic and caused great excitement in both the additive manufacturing and defense industries. This launch was Phase 1 of the partnership between the two companies, and the MoU was signed after the prototype drone launch. TAUV and Titomic agreed to a two-phase extension to their existing relationship, so that TAUV can license the TKF technology, patented in both the US and Australia, in order to make next-generation soldier systems.

According to Research and Markets, “The soldier systems market is projected to grow from USD$9.78 billion in 2018 to USD$14 billion by 2023, at a CAGR of 7.65%.”

TAUV Tactical Unmanned Aerial Vehicle at Land Forces, 2018.

TAUV worked hard to secure exclusivity with Titomic for the manufacture of its UAV and other soldier system products, like body armor and helmets. Under Phase II of the partnership, Titomic will deliver a feasibility report, which outlines mechanical properties, performance parameters, and product cost advantages of its technology, to TAUV. TAUV must outline the Specific Products on or before November 30, at a total Phase cost of $300,000, in order to execute Phase II and maintain exclusivity.

“This MoU with TAUV provides the first significant revenue for Titomic,” said Lang. “The granting of an exclusive license to TAUV for the production of solider systems further validates Titomic’s licensed CSIRO patents as a viable additive manufacturing process that enables Australian companies to manufacture cutting-edge products with competitive advantages for the global market.”

For Phase III, Titomic will design and engineer a manufacturing process for TAUV’s next-generation soldier system for up to five products, at a cost of $300,000 each, to add up to a total revenue of up to $1.5 million. Once the production and evaluation trials in this phase have been completed, the two companies will finalize product licenses so that TAUV can use the automated TKF production line systems to fabricate soldier system products…with continuing royalty payments going to Titomic for the use of its technology.

TKF uses a process similar to cold spray to build up titanium parts layer by layer, rather than simply coating a surface, and has no limits in terms of shape and size. The technology has unique additive manufacturing capabilities to offer to defense organizations for the production of lightweight, next-generation, high-performance products.

“The solider system products produced by Titomic’s TKF process will enhance the offering to defence and law enforcement agencies through improved strength, functionality and capability,” said TAUV Director Nathan Kalisch. “A new ruggedised UAV will be capable of deployment in dangerous, live combat situations to perform some of the direct combat roles we want to remove military personnel from, heightening their security.”

L-R: Titomic CTO Jeff Lang, TAUV Founder Nathan Kalisch, Titomic CEO Gilbert Michaca

This continuing partnership came about as the result from an increasing demand around the world for innovative new defense products. According to Variant Market Research, the market for combat helmets is estimated to grow to $3 billion by the year 2024, while Grand View Research states estimates that by the same year, the body armor market will be valued at $4 billion.

In the future, TAUV will be working closely with Force Ordnance to provide product innovation and advanced manufacturing solutions to some of the largest defense product manufacturers in the world.

Discuss this news and other 3D printing topics at 3DPrintBoard.com or share your thoughts in the Facebook comments below. 

[Images: Titomic]

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3D Printing News Briefs: August 28, 2018

We’re talking about business, cool products, and events in today’s 3D Printing News Briefs, followed by a how-to video on smoothing your 3D prints and a student competition project. Nano Dimension has sold two of its DragonFly Pro 3D printers to separate branches of the US military, while AIO Robotics has introduced its new silicone drawing mat for 3D printing pens. A 3D printing and design company offered a sneak peek of a new 3D printed golf product, and Rize plans to demonstrate its technology at the upcoming IMTS show. A YouTube video explains how to smooth your 3D prints using automotive primer, and Ogle Models helped a university team complete its prototype for the Unmanned Aircraft Systems Challenge.

Nano Dimension Sells Two More DragonFly Pro 3D Printers

Israeli additive electronics provider Nano Dimension announced this week that it sold two of its industrial DragonFly 2020 Pro PCB 3D printers to two different branches of the United States Armed Forces. The 3D printer sales were closed by Fathom and TriMech Solutions, two of the company’s top US value added-resellers. This news comes just two months after the company became a certified vendor for the DoD with its Commercial and Government Entity (CAGE) code, which means it can pursue and conduct business directly with the US Federal Government and its agencies.

“Nano Dimension continues to strengthen its position in the U.S. market, particularly in the U.S. defense sector. These sales to tier one customers demonstrate the attractiveness of our additive manufacturing solution,” said Simon Fried, President of Nano Dimension USA. “The ability to create functional circuit prototypes quickly and securely in-house is a key factor in the increasing adoption of our solution in the multi-billion-dollar U.S. defense sector. Nano Dimension’s DragonFly Pro 3D Printer makes it possible to 3D print radically new designs and improve workflows by leveraging the agility of additive manufacturing. The defense sector is highly motivated to enable additive manufacturing in the field by bypassing traditional manufacturing processes.”

AIO Robotics Introduces Silicone Drawing Mat

High-tech startup AIO Robotics, creator of the ZEUS All-In-One 3D Printer, is introducing its latest innovation – a silicone mat perfect for drawing on with your favorite 3D printing pen. The mat, made out of premium, heat-resistant silicone material, is available on Amazon for just $12.99, though you can save 10% on the mat when you also purchase one AIO Pen or an AIO Pen Filament.

The Silicone Mat for 3D Pen Drawing is perfect for many materials, including PLA, ABS, and PETG, and can be used for simplified but high-precision 3D drawing of grids, circles, and rectangular shapes. When you purchase the mat, you will also receive two free silicone finger protectors, which allow you to safely and easily remove filament from a hot 3D pen tip.

3D Printed Golf Ball Accessory

3D printing and design company Two Brothers 3D Printing Solutions, based in Massachusetts, offers consulting, 3D printing, and CAD services, and also works hard to, as its website states, “showcase the incredible and affordable technology that is 3D printing.”

“Over the past 4 years, brothers Ryan and Tyler Stacy have spent countless hours learning the ins and outs of 3D printing. Over that time, the two have been able to use 3D printing to create solutions for many different areas; from power tools to prosthetics, replacement parts, birthday gifts, and quite literally, anything in between.”

Earlier this week, the company posted its latest unique 3D printed solution on Twitter – a moveable contraption, called a TeeMate, used to pick up golf balls so golfers do not have to bend down to do it themselves. Fore!

Rize to Showcase Its Technology at IMTS

At the upcoming IMTS 2018 show, 3D printing company Rize will be showcasing its technology at the booth belonging to Fuji Machine America Corporation. Rize makes industrial 3D printing safe and easy with its Rize One hybrid 3D printer, and can produce parts that have best-in-class strength in all axes. Additionally, thanks to its unique ink marking capability, the company also provides what it calls “the industry’s only Digitally Augmented Part capability for traceability and compliance.”

At IMTS 2018, representatives from Rize and its authorized reseller, Dynamic Machine, will demonstrate the technology’s quick and clean support removal, and explain how the company’s industrial 3D printing can be combined with Fuji’s comprehensive automated manufacturing solutions in order to provide significant cost and time advantages. Come see the Rize One for yourself, and get all your questions answered, at Fuji’s booth #339059 at the IMTS 2018 show, September 10-15 at McCormick Place in Chicago.

Smooth 3D Prints with Automotive Primer

We’ve seen people smooth their 3D prints with epoxy and with acetone, but this is a new one – automotive primer. Youtuber gordontarpley recently published a video about how well it works to smooth your 3D prints with 2k automotive primer, saying that it’s been his “main method for the last few months.”

“I get asked all the time, ‘How do you clean up your 3D prints?’ and the method always varies. So I’ve been trying to figure out the best way to make a video about that,” Tarpley said.

“Most of the time I go straight from a 3D print…and I will just start with primer. Primer paint and then I’ll paint a layer, sand it, paint, sand, over and over until it looks smooth.”

Tarpley said that’s he learned some valuable information about the primers in this way. To learn more about smoothing your 3D prints with automotive primer, check out the video below:

3D Printed Prototype for Unmanned Aircraft Systems Challenge

Prototyping company Ogle Models and Prototypes has a history of helping student university teams with their competition projects. Recently, the company worked with a team from University College London (UCL) to create an unmanned aircraft prototype for their entry in the Unmanned Aircraft Systems Challenge, which is held by the Institutions of Mechanical Engineers and designed to develop and inspire the next generation of engineers.

The student team had to design, manufacture, and operate an unmanned aircraft that could complete several tasks simulating a humanitarian mission. The team ran into some issues – in order to endure wind tunnel testing, their prototype would need pressure taps in order to sample air distribution across it. So they called on Ogle for assistance, which recommended SLA 3D printing for the job so they could lower costs by building the taps within the model.

“The accuracy of industrial SLA ensured that the complex geometry of the scaled-down aerodynamic surfaces was replicated with precision. For clarity reasons, the team chose ClearVue resin, which allowed the pressure tapping pathways to be seen on the finished model,” explained Matt White, Senior Sales Engineer at Ogle.

“UCL is regarded as one of the best institutions in the country when it comes to training tomorrow’s mechanical engineers and we were only too happy to help when the team approached us.”

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