3D printing in drone manufacturing: Rama Krishna

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3D printing in drone manufacturing: Rama Krishna

3D printing in drone manufacturing: Rama Krishna

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Feb 18,25

Using 3D printing, companies can produce complex geometries for drone components that optimise performance and reduce weight. For instance, nano drones leverage 3D-printed frames made from advanced composites, ensuring durability without compromising agility, says Rama Krishna, Co-Founder & CEO, EndureAir.

3D printing in drone manufacturing: Rama Krishna

As industries shift toward the development and adoption of advanced drone or UAV technologies, drones have emerged as a crucial solution in reshaping various sectors like defence to civilians. Companies in unmanned aerial vehicle (UAV) systems, harness cutting-edge technologies to design and manufacture lightweight, efficient, and highly adaptable nano and logistics drones.

Advanced drone manufacturing technologies have revolutionised the industry by offering unparalleled long-range operation, payload capacity, and customisation.

One of the most difficult problems in drone design and manufacturing is achieving an aerodynamic, minimal operating weight. Weight and power must be carefully balanced while using drones. Many drones are currently dealing with a troublesome loop. Specifically, they run on batteries and need larger power reserves for transporting cargo. They need larger batteries to produce more power. However, larger batteries increase weight, which necessitates more power to offset, which calls for larger batteries, which in turn calls for more power, and so on. Currently the startup integrates technology advancements to achieve excellence in drone design and production. Advanced aerodynamics and lightweight materials can enable payloads of up to 100 kg, with the potential for increased capacity.

Although carbon fibre is a strong material option for general use, manufacturers must take into account a wide range of criteria when choosing drone material. Near all manufacturers of UAVs use carbon fibre composite material. Over time, lightweight elements of carbon fibre gradually replaced heavy metal components, enabling greater acceleration and higher speeds.

Stiffness plays an important role in aircraft applications. To preserve its aerodynamic shape, the hardware structure must, first and foremost, have a high level of structural stiffness. Second, high rigidity is necessary for rotating blades like rotors, propellers, engine fan blades, and structures going through pressurisation cycles. Otherwise, the thrust would deform the blade profile and lower propulsion efficiency.

Composites are hard to beat when it comes to dependable drone materials. Drones must be able to connect to ground stations via satellite or wireless communications as they are unmanned aircraft. Composites can be made to pass some electromagnetic frequencies while absorbing others. They are therefore frequently employed to build weather-proof, structural enclosures that shield the broadcast and receive antennas.

Additive manufacturing (3D printing) has also transformed how drones are built by enabling lightweight and robust structures. Using 3D printing, companies can produce complex geometries for drone components that optimise performance and reduce weight. For instance, nano drones leverage 3D-printed frames made from advanced composites, ensuring durability without compromising agility.

However, additive manufacturing also enables part consolidation and the creation of tight packaging of subcomponents, which are two further ways that 3D printing might reduce drone weight. For instance, there are heavy and time-consuming components that make up a fan in a ducted cooling system. This fan can be reduced to a single component using design for additive manufacturing. Nevertheless, the advantages extend beyond design. Manufacturers can now maximise the mass of UAVs thanks to this capability.

Additionally, additive printing speeds up prototyping, enabling quick design testing and improvement. This flexibility is essential for meeting the ever-changing needs of surveillance and logistics applications.

Production procedures have been reduced by automation and robotics, guaranteeing efficiency and uniformity. Robotic systems in assembly lines allow for exact component integration, which lowers human error and improves quality control. For logistics drones produced in bulk, where precise construction is essential for payload stability and flying efficiency, this is especially crucial.

A key component of contemporary operations is digital transformation. Digital twins save time and money by simulating and optimising drone performance in a variety of circumstances, spotting possible problems before they are physically manufactured.

Using IoT-enabled sensors, Industry 4.0 concepts also make it possible to monitor manufacturing processes in real-time, guaranteeing that strict quality standards are met. Given that logistics drones frequently operate in harsh settings, this functionality is essential for ensuring reliability.

Drones are used in the military for a variety of purposes, such as reconnaissance, target acquisition, surveillance, and intelligence gathering. Additive manufacturing could be very helpful in these endeavours.

As the military increasingly depends on UAVs to complete missions, on-demand manufacturing and repair could become essential. In a location where distribution is challenging or in a scenario where speed is crucial, they could need a drone or spare parts like the propeller soon. Local manufacture made possible by additive manufacturing, maybe the most dependable and expedient buying strategy in this instance.

Artificial intelligence (AI) and machine learning are essential to the production and use of drones. Machine learning algorithms evaluate sensor data throughout production to forecast maintenance requirements and boost workflow effectiveness. Through autonomous navigation and real-time decision-making and AI improves drone performance after manufacture, allowing for smooth operation in challenging logistics situations.

In the production of drones, sustainability is becoming more and more important. Energy-efficient procedures and material recycling are examples of eco-friendly activities that are increasingly commonplace. To lengthen their lifespan and lessen their environmental impact, logistics drones are frequently built with modular components that are simple to repair or replace.

Nano drones are designed for accuracy and maneuverability, which make them perfect for uses like environmental monitoring and spying. These little UAVs have advantages. Cutting weight without sacrificing structural integrity is possible with advanced materials. Electronics that are smaller in size are high-performance features in a small form factor made possible by precision engineering. Modular design increases versatility by being easily modified or swapped out.

Drones for logistics meet the increasing need for dependable and effective delivery methods. Lifting payloads is made possible by advanced aerodynamics and lightweight materials, with the possibility of an enhanced capacity. Possessing long-range capabilities, the extended operations are made possible by high-efficiency propulsion systems, which make them perfect for inter-city logistics and deliveries. Even in difficult terrain, autonomous navigation with AI-driven technologies guarantees safe and effective operations.

The drone business is dedicated to expanding the capabilities of unmanned aerial vehicles. The goal is to establish new standards for UAV performance and dependability by consistently investing in cutting-edge manufacturing technologies. The goal is to develop drones that not only satisfy present demands but also foresee those of the future.

Drones are at the vanguard of innovation as the world transitions to a more automated and connected future, enabling companies to take advantage of possibilities and overcome obstacles. Advanced manufacturing demonstrates its potential to revolutionise businesses and provide significant solutions in a variety of fields through nanotechnology and logistics drones.

Drones must fulfil the requirements. Many businesses that provide goods and services in the aerospace sector strive to obtain certifications since the industry has a set of design and production standards that promote strong confidence in the UAVs dependability.

Quote: In the production of drones, sustainability is becoming more and more important. Energy-efficient procedures and material recycling are examples of eco-friendly activities that are increasingly commonplace.

About the author:

Rama Krishna, with a strong foundation in aeronautics, specialises in structural and experimental aerodynamics. Over time, he has broadened his expertise to include operations, legal, and finance, playing a pivotal role in the inception and growth of EndureAir. An alumnus of IIT Kanpur with a Bachelor's and Master's in Aerospace Engineering. Before its establishment, Rama worked in a research group led by Dr Abhishek, Director, EndureAir, focusing on wind tunnel research and drone performance enhancement. This collaboration included consulting for defence organisations, private companies, and DRDO labs.

Since joining the group in 2016, Rama gained entrepreneurial experience by addressing R&D gaps for partner organisations. This laid the foundation for EndureAir’s business model, which provides customised solutions for aerospace and defence. Officially launched in 2019, EndureAir began with consulting projects, including one with Delhivery to develop logistics drones. Over time, the startup shifted focus toward offering ready-to-use drone solutions for logistics and surveillance.

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