Composite Materials in Drone Design
Karman Drones
Karman Drones mission is to Improve human existence with limitless unmanned aerial technology.
OVERVIEW
Composite materials have been used by humans for thousands of years, dating back to the ancient Egyptians and their use of papyrus and reeds to create boats and other structures. The concept of combining different materials to create a stronger, more durable product has been a key part of human ingenuity, and has been applied in a variety of different fields and industries throughout history.
In the 20th century, advances in Materials Science and Engineering led to the development of new types of composite materials, including fiberglass and carbon fiber. These materials were used in a wide range of applications, from aircraft and spacecraft to sporting goods and automotive components.
Today, composite materials find its application in a wide range of industries, including aerospace, construction, and transportation. They are valued for their unique combination of strength, stiffness, and lightweight properties, and are used to create structures and products that are stronger, more durable, and more efficient than those made from traditional materials.
Composite materials have become increasingly popular in the design and construction of drones in recent years. This is due to their unique combination of strength, stiffness, and lightweight properties, which make them ideal for use in the construction of aerial vehicles.
ADVANTAGES
One of the key advantages of using composite materials in drones is their ability to provide a high strength-to-weight ratio. Hence the structures made are lightweight and can withstand significant stresses and strains, without adding unnecessary weight to the drone. This is particularly important in the design of drones, as every ounce of weight that can be saved will translate into improved performance, range, and payload capacity.
Composite materials are also highly resistant to fatigue, making them ideal for use in applications where the drone will be subjected to repeated stresses and strains over time. This is important in the case of drones that are used for extended periods of time, such as those used for aerial photography or surveillance.
In addition to their strength and durability, composite materials are also highly resistant to corrosion and weathering. This makes them ideal for outdoor applications. They can withstand exposure to wind, rain, and other environmental factors without degrading or losing their structural integrity.
Another key edge composite has materials over others is their ability to be molded into complex shapes and designs. This allows designers to create highly efficient and aerodynamic structures that are optimized for maximum performance and efficiency. This is particularly important in drones that are designed for high-speed or long-range applications, where every aspect of the design must be carefully considered to ensure the best possible performance.
ISSUES
One of the major issues in the manufacture of composite materials is the formation of defects, such as voids, pores, or inclusions, which can weaken the final product and reduce its overall performance. These defects can be caused by a variety of factors, including improper mixing of the raw materials, uneven heating or cooling during the curing process, or inadequate quality control.
To address this problem, manufacturers of composite materials are turning to advanced technologies, such as
These techniques can help to reduce defects and improve the overall performance of the final product.
INDUSTRY USAGE AND DEVELOPMENT
From a military aspect, stealth technology is essential for modern warplanes to avoid enemy air defense and radar surveillance. Drones have even higher requirements for stealth technology. Current stealth technology includes material stealth, coating stealth, plasma stealth, structural design.
Prioritizing research on the stealth design and manufacturing technology of composite foam or honeycomb sandwich structures will help us improve stealth technologies. RTM (Resin Transfer Molding) and RFI molding processes can reduce the number of composite parts, lowering cost and increasing efficiency, but more research is needed on the relationship between design, mechanical properties, and configuration in these processes. Further study of the mechanical properties of RTM and RFI molded composite structural members is crucial for low-cost, high-efficiency, and cost-effective UAV structural platforms.
Other areas of focus for UAV manufacturing technology include low-cost manufacturing, rapid composite non-destructive testing, and intelligent material design/manufacturing. Another way to bring down cost is to use FDM (Fused Deposition Modeling).
THE FUTURE
As the market share of drones increases in civil and military applications, the demand for more maneuverable, pay-load effective UAVs is going to increase with composite materials playing a vital role in the development of these new aircraft. The factors which are fueling this growth can be attributed to the increasing need for weight reduction in unmanned systems and increased reliability and durability of composite materials. According to a report published by MarketsandMarkets in 2021, the global market for unmanned military drones is expected to grow at a compound annual growth rate (CAGR) of 7.3% from 2022 to 2027, reaching a value of $17.0 billion by 2027. The current value of the market in 2022 is $12.0 billion. The report cites increasing demand for unmanned vehicles in various applications, such as military and defense, agriculture, and inspection and maintenance, as a key factor driving the growth of the market. As the market for drones continues to grow, the use of composite materials is likely to become even more widespread, leading to the development of even more advanced UAVs.