Nov 17, 2015 | By Benedict

Whilst we are constantly inundated with news of car manufacturers steering towards 3D printing in order to produce prototype parts, the use of additive technology has also skyrocketed in the field of aeronautical engineering. Less than a month ago, one maker demonstrated how 3D printed propeller blades could function almost as effectively as their injection molded counterparts, proving that functional 3D printed components can be produced for small flying craft. Despite the success of various projects like that one, the aeronautical use of additive manufacturing is generally restricted to the prototyping stage, rather than mass production of parts.

One company to effectively use 3D printing to produce prototypes before employing subtractive manufacturing techniques for its final product is Ascent Aerosystems. The Arizona based firm has been presented with this year’s Proto Labs Cool Idea! Award, a service grant given to innovative companies by CNC specialist Proto Labs, Inc. Ascent received the award for Sprite, a compact and rugged drone built by the company and which will soon be taken into production thanks to a successful Kickstarter campaign.

According to the Consumer Electronics Association, more than 700,000 drones are expected to be sold in the U.S. this year. “Drones are already playing key roles in a variety of industries, and for military and public safety applications,” said Proto Labs founder Larry Lukis. “This particular drone is innovative because of its consumer-friendly design: a smaller size, greater durability and ease of use.”

The prize-winning Sprite collapses to the size of a water bottle and uses a coaxial rotor design—one rotor stacked on top of another. The company has started using injection-molded parts for its prototype parts, after initially 3D printing their components in PLA and ABS-like plastics. “While that was great for our initial development, that process didn’t provide the parts with the durability we required,” explained Jonathan Meringer, co-founder. “The injection-molded polycarbonate parts (from Proto Labs) represent production-grade quality that’s added a dramatic improvement in everything from flight performance to assembly and maintainability. We were able to build several conforming vehicles that are really close to what the final product will be.”

That final product is due to boast some impressive features. The drone features a fully autonomous autopilot with GPS, a 2-axis GoPro-compatible gimbal, and real-time telemetry. The aircraft measures 13.2” in length and 3.8” in diameter, weighing just 2.6lbs with battery and standard camera. The Sprite can fly for approximately 10-12 minutes, at speeds of up to 10m/s. The signal range stands at around 2km with standard equipment, but distances of up to 50km are possible with long range gear.

Ascent’s Kickstarter campaign for the formerly 3D printed Sprite drone raised a total of $406,061 from enthusiastic backers, after an initial target of $200,000 had been set. The Sprite, which is due to retail at $699, will hit the market in the second quarter of 2016.

 

 

Posted in 3D Printing Application

 

 

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