Carbon Fibre Composite Drone Design & Product Render

The Challenge:

1. To design a professional level drone utilising a lightweight, high strength, tough carbon fiber body suitable for high volume manufacture.

2. To develop realistic rendered media of the drone. Aim: demonstrate the early design concept to generate interest for next level investment.

Rendered image of the drone design concept

Design Solution

A design was developed around a body structure made using carbon fibre skins sandwiching a central moulded plastic core to house all electronics, battery & camera.

Shock absorbing landing feet design for soft landing, minimising damage from high impact landings.

Front facing camera location.

A snap cure prepreg epoxy resin system capable of cycles time of 2-3 minutes using match metal compression mould tooling (Upper + lower skin parts per tool) was chosen for the structural carbon fibre material.

Prepreg materials cut to profile using high speed cnc cutting table enable precise skin cutting and alignment in the tool.

Compression moulding of the skins to be performed at 150C, supporting daily batch manufacture of 350 parts per tool / 7 hr shift.

The central plastic moulded core, prototyped using 3d printed high strength engineering thermoplastic Onyx, volume manufacture using injection moulding.

Common Design for Prototype & High Volume Manufacture

Process chosen aligning prototype & end manufacture solutions

Render Solution

Combination of static images and animation videos of the drone in flight.

With & without background.

Licensing

This drone design is available under licencing. Interested? We would be more than happy to discuss. Contact us