Project Casper
Inventor of an electric unmanned aerial vehicle (UAV), Karthik Bomaiah, contacted us to help him reduce the weight of his aircraft by replacing current aerostructures with lightweight carbon fibre-reinforced polymer (CFRP) composite aerostructures. The UAV, Casper, was fitted with bespoke remote-controlled camera platform, and can switch from hovering calmly to carrying out instant acrobatic manoeuvres when required. The UAV configuration was unique and interesting at the same point. This helped making action movies more realist than just relying on special effects. We were able to assist Karthik with the design, development and manufacture of advanced composite components for his UAV.
The ask
After having some discussions with the customer and understanding their exact needs, we set out to deliver the following:
- An optimised design of UAV components incorporating advanced composite materials.
- A detailed insight of selecting most feasible composite processing technique that can be use for producing superior quality UAV components, for both low and high production volumes.
- Cost estimates for supplying conforming composite wing, empennage, propeller ducts and a fuselage.
- Cost estimates for associated patterns and tooling.
- Supply of composite UAV components with certificate of conformity.
What was delivered
We studied and optimised the designs of the following components for better operational performance, efficiency and durability:
- Wing
- Empennage
- Propeller Ducts
- Fuselage
A detailed report containing the most feasible composite manufacturing processes, along with down-selected manufacturing and control plans for producing the above components in both high and low production volumes was provided. The processes suggested were:
- Prepreg composite moulding using Industrial Ovens and Autoclaves
- Resin transfer moulding
- Heated press/compression moulding
Furthermore, patterns were 3D printed in-house, mould tools, fit-check tools, mounting jigs and machining fixtures were designed and sourced from trusted suppliers when not manufactured in-house.
UAV components were build-to-print in-house. The manufactured parts were thoroughly inspected for any dimensional non-conformity, manufacturing defects, mis-machining or mis-assembly.
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