Drone Components
This case study demonstrates an industry (aerospace) which would benefit from the material properties of ISF products just as much as from the flexibility of a dieless process.
Background: replacement cover plates for drones
Aerospace components may operate within the atmosphere or in outer space, and are often required to be strong, lightweight and complex.
The applicability of ISF in large aerospace devices is limited to small part sizes and small production runs — for example, ISF cannot be used for very large sheet metal parts like aircraft fuselages or external body panels.
However, small aerospace technologies such as unmanned aerial vehicles could make use of ISF. Lightweight, thin metal could be used as external body plates.
ISF Steps
The geometry of the cover plate is designed in CAD software.
The geometry is adapted to be manufactured using ISF.
A toolpath is generated to be used by a CNC machine.
The part is formed.
The part is finished, painted and fitted.
Benefits
ISF can produce complex contours which would allow the external body panels to be fitted perfectly to internal components, optimising space usage.
The option for dieless production would improve long-term serviceability by ensuring availability of replacement panels, even for outdated models.
Viability
Because wall angles cannot be vertical, a panel created as demonstrated in this case study can only act as a top cover and not wrap around or fully encase a drone by itself.