Drones are becoming increasingly complex, with recent projects highlighting their ability to travel autonomously, often for extremely long times before needing to refuel.

Now, researchers are turning their attention to how the devices are made.  A project, which made its debut at the recent Dubai Airshow, used 3D printing to construct a jet powered drone.

The machine is believed to be the most complex flying device ever constructed using 3D printing.  It has a 9 foot long wingspan and an aerodynamic design.

3D printed drones

Roughly 80% of the drone was constructed using 3D printing, and the makers reveal that it is capable of flying at over 150mph.

“To the best of our knowledge, this is the largest, fastest and most complex 3D-printed UAV ever produced,” they say.

The drone consists of several hollow parts that were constructed using fused deposition modeling (FDM).  This is when molten plastic is placed onto a surface layer by layer until the object is formed.

“Aurora’s UAV is clear evidence of FDM’s ability to build a completely enclosed, hollow structure which, unlike other manufacturing methods, allows large — yet less dense — objects to be produced,” the team say.

The bulk of the plane was made using ultem, which is highly resilient and flame resistant.  The substance is made out of thermoplastic resin.

Production times

By 3D printing the device, it reduced the time to construct it by approximately half.  It was also significantly cheaper than making the device using more traditional methods.

It’s a nice example of how 3D printing could be incredibly valuable for the construction of lightweight aircraft, such as drones.  The approach has already made inroads into the UAV market, with researchers from the University of Southampton launching just such an aircraft earlier this year.

It’s certainly an exciting area that has huge potential for revolutionizing the drone market.  Check out the video below to see the craft in action.