Low Cost Flatpack Aircraft with Ultrasonic Additive Manufacturing

Our successful Phase I program demonstrated a versatile aircraft that seamlessly scales from micro-UAV (Group 1) to medium altitude long endurance (Group 4) vehicles. Leveraging production proven 3D printing techniques, the team reduced weight by 24.8%, reduced assembly time by 80%, and increased payload by 8.86 lb or 45%. By strategically integrating multiple functions into each 3D-printed part, our aircraft components enable dense packaging. Imagine the possibilities of rapidly assembling these aircraft in large quantities to launch overwhelming attacks against targets. We can store a squadron in a CONEX box and assemble in the field.With a Phase II program, the team will further refine both the design and manufacturing steps propelling this initial concept into a high-performance, lightweight, and mass-producible production model. We will have a Group I or Group II prototype at the end of Phase II with interchangeable and interoperable components.