3D-printed drone features embedded electronics

Singaporean researchers have 3D-printed a ready-to-fly drone with embedded electronics using aerospace-grade material. The drone was developed by Nanyang Technological University (NTU Singapore) and Stratasys Asia Pacific, a subsidiary of 3D printing company Stratasys.

A quadcopter with four rotors, the drone was designed, 3D-printed and flown by Phillip Keane, a PhD candidate from the university’s Singapore Centre for 3D Printing (SC3DP). The electronics were incorporated in the drone during a 3D printing process which employs Stratasys ULTEM 9085 — a high-strength, lightweight, 3D-printable thermoplastic certified for use in commercial aircrafts.

In 3D printing, objects are created digitally layer by layer until completion. However, embedding electronics can be a challenge, as most will not survive the high temperatures of the 3D printing process. As part of the NTU project, commercial-grade electronics had to be modified and placed within the drone at the various stages of the printing process.

“We had to add some heat-proofing modifications to the components to ensure they could last,” said Keane. “This involved adding new components to the printed circuit boards and also designing custom housings.

“The housings which were pre-printed in ULTEM 9085 also provide a flat surface for the 3D printer to continue printing over them,” Keane added. ULTEM 9085 is prized for a high strength-to-weight ratio and FST (flame, smoke and toxicity) rating, making it suitable for the commercial transportation industry — especially aerospace.

The components survived the high-temperature printing, which reached over 160°C and took just under 14 hours. There were just three pauses for the electronics to be placed within the chassis; the motors and the propellers were mounted after the entire chassis was completed.

In addition to being extremely rugged, the drone is capable of supporting over 60 kg of weight suspended from its structure. Keane said the next version of the drone will feature better durability, lighter weight and improved flight dynamics.

“This project exemplifies the power of Stratasys’s flagship fused deposition modelling (FDM) 3D printing technology and perfectly demonstrates the strength of the ULTEM resin,” said Fred Fischer, director – applications and products, Stratasys Asia Pacific. “We look forward to researching, developing and unveiling more possibilities with 3D printing and materials as we work with industry partners and academia.”

Image courtesy of Nanyang Technological University.