HP Additive Manufacturing Supports EIVIE in Developing NDAA-Compliant Drone

Innovative Drone Manufacturing Through Additive Technology

Challenges in Drone Development

As the drone industry evolves, manufacturers face increasing challenges. Customers are seeking enhanced capabilities, while regulations necessitate modifications to components. Additionally, supply chain constraints compel manufacturers to redesign critical elements such as motors, GPS receivers, and electronics. Traditional manufacturing methods often lead to delays, as even minor changes can require new tooling and extensive engineering efforts.

US-based drone manufacturer EIVIE encountered these challenges while developing a unique aircraft designed to meet National Defense Authorization Act (NDAA) compliance without compromising its aerodynamic vision. The company leveraged HP’s additive manufacturing technology to achieve this goal.

Designing for Flexibility

EIVIE’s approach to drone design is distinct from conventional models. The company’s aircraft features smooth curves and an elegant appearance, prioritizing aerodynamic performance over manufacturing convenience.

Co-founder and CEO Damjan Zabovnik, who has a background in engineering and a passion for aerodynamics, emphasizes the importance of maintaining design integrity while adhering to regulatory requirements. This necessitated the replacement of major components, such as motors and GPS systems, which in turn affected the entire airframe.

“We knew we wanted an NDAA-compliant aircraft, and that meant changing major components,” Zabovnik stated. “Different motors and GPS units mean different attachment points throughout the airframe. With additive manufacturing, we simply update the CAD model and print the next iteration. We don’t have to build new molds every time, so we can keep improving the design instead of waiting for tooling.”

Zabovnik anticipates that this flexibility will be crucial as regulations and available components continue to evolve.

Aerodynamics and Performance

The EIVIE airframe exemplifies the advantages of additive manufacturing. Its intricate design enhances aerodynamic performance, a feat that would be difficult to achieve with traditional manufacturing methods.

“Our airframe is very complex,” Zabovnik explained. “You can’t just bend sheet metal into this shape. We worked with HP because we wanted to manufacture exactly what we designed. We can’t compromise on aerodynamics.”

Historically, aircraft designs have been constrained by manufacturing limitations. Additive manufacturing allows engineers to prioritize flight performance, enabling more innovative designs.

Engineering Considerations

Creating drone components involves a multifaceted approach that considers weight, center of gravity, structural integrity, and aerodynamics. Clara Quinquilla, Drones Segment Manager for HP Additive Manufacturing, noted that optimizing drone components is more complex than in many industrial applications.

“When you design for additive manufacturing from the beginning, it becomes a powerful engineering solution,” Quinquilla stated. HP provides support to manufacturers by optimizing parts for additive production, which can reduce weight and improve efficiency.

Zabovnik highlighted the material properties of HP’s Multi Jet Fusion technology, which offers strength in all directions, akin to metal, enhancing the reliability of structural components.

Production Scaling and Future Prospects

While rapid prototyping is often associated with additive manufacturing, both HP and EIVIE view production scalability as a significant advantage. Quinquilla emphasized that manufacturers need to produce larger quantities of drones efficiently.

• Design optimization allows for more parts to be produced in each run.
• Streamlined assembly processes can lead to reduced costs.

Zabovnik believes that additive manufacturing simplifies business scaling, stating, “Printing is one of the easiest ways to scale effectively. Traditional manufacturing requires more tooling, more suppliers, and much more supply chain management.”

Domestic Manufacturing and Innovation

EIVIE operates in the United States, with facilities in Oregon and California, and has participated in Pendleton’s drone accelerator program. Zabovnik advocates for advanced manufacturing in the U.S., citing the potential for innovation and the availability of skilled talent.

“There are tremendous opportunities to build advanced products in the U.S.,” he remarked. “As manufacturing becomes more advanced, innovation becomes a competitive advantage.”

Looking ahead, Zabovnik believes that the evolution of aircraft design is just beginning. “For a long time, aircraft looked the way they did because that was what manufacturing allowed. Now those limits are disappearing. We’ll see much more innovative structures, and with AI helping engineers design them, that evolution will accelerate.”

For EIVIE, additive manufacturing has proven to be more than a means of rapid prototyping; it has enabled the company to maintain its design vision while adapting to regulatory changes and preparing for increased production capacity in the U.S.