Dragonfly UAS mainly uses 3D printing to make UAV test flight models. Dragonfly UAS’s main UAV is the Vito model. Although quadcopters fly stable but slow, the Vito model flies faster and can collect large-scale data in a short time. Dragonfly UAS is positioned to develop high-end multi-rotor and fixed-wing integrated models, which are more complicated to operate. Therefore, before delivery, they make small models for customers to practice test flights. At the same time, they use FFF printers to produce some jigs and other auxiliary tools.
In order to meet the market demand for complex structures and rapid iterations, Dragonfly UAS chose the Raise3D Pro3 printer, achieving a full range of innovation from design to production. The Pro3 effectively addressed challenges in UAV prototype verification and was also leveraged for printing fixtures, end-use part production, and more.
Chris Lee, Senior R&D Design Engineer of Dragonfly UAS, with Raise3D Pro3 equipment.
Challenges facing Dragonfly UAS
Dragonfly UAS went through a transition from using fiberglass casting, Delta 3D printers to Raise3D Pro3 printers. They faced a number of challenges:
- Long production cycle
In the early days, they used fiberglass molding to manufacture drone parts, which was not only time-consuming, but also difficult to maintain the consistency of each part. Fiberglass can also be harmful to humans to the human body.
- Difficulty in prototyping
They had used a Delta 3D printer before, which could meet basic needs but had a lot of problems. For example, the printer had no cavity, so the equipment life was short; the printing speed was slow; the dimensional accuracy was insufficient, and the tolerance of each batch of models would also be different, especially the tolerance of the holes, which would reach to more than 0.3-0.4mm.
- Material restrictions
Drones require lightweight and high strength fuselages, and finding the right combination of materials is a big challenge. In addition, manufacturers of Delta 3D printers do not provide slicing software and templates that are suitable for filaments, which brings difficulties to their research and development. Chris Lee, a senior R&D design engineer at Dragonfly UAS, said, “R&D needs to consider a lot when introducing new materials, not only physical properties but also printing stability, so changing materials is troublesome. We have to carefully evaluate each filament.”
- Cost control pressure
While ensuring product quality, Dragonfly UAS must also consider how to effectively reduce development costs and enhance development convenience.
Therefore, a complete solution of printers, filaments, software, and after-sales services are their best choice.
The drone fuselage printed using Raise3D Pro3.
Reasons for choosing Raise3D and the changes it brings
Faced with those challenges, Dragonfly UAS chose the complete solution provided by Raise3D, which includes: Pro3 Series 3D printers, ideaMaker slicing software, and high-quality pre-sales and after-sales services provided by Raise3D’s Taiwan partners. There are profound technical considerations behind this decision:
- High precision and high speed
Compared with the previous Delta 3D printer, the printing speed of Raise3D Pro3 has been increased to 150mm/s-200mm/s, and the time to complete the same task has been shortened from one week to one day. Our high-speed printing ensures dimensional accuracy of the model, keeping tolerances controlled within 0.2mm. High Chris Lee said, “After we purchased the Raise3D Pro3 printer, it got better and better, and we directly started to print the fuselage. The same thing used to take a week with a Delta printer now only takes one day with the Pro3. The tolerance of some components can reach 0.1mm, and they can be assembled on the drone immediately.” This has greatly improved the R&D efficiency of Chris Lee’s team.
They use Raise3D Pro3 to print the weight box.
- Stable and reliable performance
Raise3D Pro3 has a closed cabin design, which deters environmental factors on the printing process. At the same time, it’s hardware configuration and preset parameters also ensures stable printing quality so that the need to frequently adjust parameters due to material changes is reduced.
Even during high-speed printing, the print quality remains consistent/stable across the same batch and between different batches of models. Chris Lee said, ” In the early days, Delta 3D printers were open with no cabins, no slicing software, and no templates for third-party filaments. Every when the filament are changed, the parameters had to be readjusted to ensure stable printing.”
Using Raise3D Pro3 to print the weight box.
- Flexible and diverse material support
In addition to the commonly used PLA material, Dragonfly UAS also tried different types of materials such as Raise3D Premium PLA and Raise3D Premium ASA to adapt to different application scenarios. In particular, for outdoor use, they hope to obtain white ASA material to better resist UV aging.
The fuselage printed by Raise3D Pro3.
- Optimized workflow
With the powerful functions of ideaMaker, engineers can easily set printing parameters, such as creating support structures that are easily removable, thus simplifying post-processing steps.
The fuselage printed by Raise3D Pro3.
In-depth application examples
After Dragonfly UAS became proficient in using the Raise3D Pro3 printer for drone prototype verification, they began to try more in-depth applications. Dragonfly UAS began to directly use the 3D printer to make the main structure of the drone. This not only speeds up product development, but also allows the team to flexibly adjust the design plan according to actual needs. In addition, they also use the Pro3 printer in the following applications:
- Functional testing and weight simulation: When conducting functional testing of an aircraft, it is crucial to accurately control the weight and center of gravity distribution. Using Raise3D Pro3, Dragonfly UAS can quickly manufacture weight blocks that meet the requirements for simulated test flights to ensure the balance and stability of the aircraft.
- Customized manufacturing of auxiliary tools and fixtures: In addition to core components, various auxiliary tools and fixtures can also be efficiently produced through FFF technology. This method not only reduces procurement costs but also customizes the most suitable tools according to specific work conditions and improves efficiency.
Motor mount printed using ASA filament.
Deepening the collaboration of Raise3D
Looking ahead, Dragonfly UAS plans to continue to deepen its cooperation with Raise3D to explore more possible application areas and technology upgrade directions. For instance, enhance the design of current support structures to make them more material-efficient and easier to disassemble. In addition, Dragonfly UAS is actively looking for more durable printing platform sticker materials to further improve printing quality and user experience.
This case is shared by Kiden Trading Ltd., Co., Raise3D’s sales partner in Taiwan.
