Showcasing the potential of lightweight 3D printed drones in visual inspection and logistics handling applications

Drones, or Unmanned Aerial Vehicles, are one of the youngest flying objects we know these days, with their public breakthrough for commercial use only about 20 years ago. In industry they have been applied much longer, though. They are used in e.g. agriculture, warehouse monitoring and inspection, logistics, and many other industries. Being relatively small, operating unmanned, and providing an overview of situations from above, it is interesting to explore new applications and improvements for drones and drone components in industry.

Manufacturing drones and drone components tailored to specific applications can lead to better performances by utilising optimal resources. This is also the project goal of MIND; which is an acronym of Manufacturing Innovations for Nextgen Drones. The MIND project consortium is built of Corvus Drones, LogiXair, and Bolk. Corvus is specialised in indoor greenhouse crop monitoring and inspection, LogiXair develops drones for logistic operations, and Bolk is a large logistics operator with its own warehouse.

Corvus and LogiXair are both experiencing a challenge to create lighter-weight drones and drone components. Producing lightweight drones requires proper material selection, properties understanding, and optimised drone geometry. Addressing this challenge leads to, amongst other things, a longer hauling flight time and complying with drone safety regulations.

Bolk, on the other hand, is currently experiencing increased efforts in monitoring and inspection time in their warehouse. Assisted by an automated drone inspection system, these efforts can be reduced without compromising the inspection standards.

Guided by the FIP-AM@UT, the organisations are bundling their forces and jointly work towards the design and development of a 3D printed drone or drone components to reduce the weight, and building demonstrators that successfully showcase the potential of these drones in visual inspection and logistics handling applications. The main focus will be on the design optimisation and material selection for additively manufactured drones, investigating the possibilities for inspection applications of drones with vision technology, and creating a proof-of-concept deliverable to show the applicability of drone technology in a warehouse and outdoor setting.

Industry partners

APPROACH

The MIND project addresses these challenges by focusing on the design and development of lightweight 3D-printed drones and
components tailored for specific industrial applications. By utilising additive manufacturing, the project aims to reduce drone weight while maintaining structural integrity and performance. This approach enables precise optimisation of drone geometry and material selection, balancing strength, durability, and weight. In addition to that topology optimisation driven by simulations can significantly assist in targeted design improvements.

Under the guidance of FIP-AM@UT, the consortium partners, each with expertise in different drone applications, collaborate to create effective solutions. Their efforts include enhancing drone efficiency for various autonomous inspection and logistics activities. The project also emphasises integrating vision technology to improve defect detection applicable to inspection capabilities. It aims to produce proof-ofconcept demonstrators that highlight the effectiveness in real-world inspection and logistics handling scenarios.

OUTCOME

The MIND project successfully showcased 3D-printed, lightweight drones for visual inspection and logistics. Optimised design and material selection led to identification of locations where weight reduction is possible, thereby enhancing flight performance and extending operational time. 3D printeddrones performed an autonomous inspections in a controlled warehouse settings, showcasing the potential to reduce manual monitoring and efficiently detect defects in structures.

The project demonstrated the applicability of innovation in different stages of drones’ development process that are applicable to both indoor and outdoor applications, including logistics and warehouse monitoring.

Key results include:

• Identification of structural locations where weight reduction enhances flight performance and extends duration
• Effective analysis of reinforcement impact on Carbon Fibre Reinforced Polymer (CFRP) material using simulations
• Autonomous inspections using integrated modules both software and hardware reducing manual effort in warehouses
• Versatility for indoor and outdoor applications, including logistics
• Effective cross-sector collaboration producing innovative, tailored solutions

This project was made possible through the Regio Deal supported by the Province of Overijssel and the Dutch State.

For more information on MIND, feel free to reach out to

Hari Subramani Palanisamy

Research Engineer

Celal Soyarslan

Senior Research Engineer

Ava Ghalayaniesfahani

Research Engineer

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