3D Printing Manufactures Key Components for the Volocopter 2X Air Taxi
The Volocopter 2X is an electric aircraft that takes off and lands vertically (eVTOL). To build it, additive manufacturing is extensively integrated, enabling the production of a large number of its structural and cabin components. This method is essential for reducing the weight of the aircraft, a decisive parameter for it to fly more efficiently and for longer in the urban environment. 🚁
Optimize Design and Produce with Agility
By manufacturing parts in 3D, engineers can redesign their internal geometry, creating honeycomb or hollow structures that are very lightweight yet maintain the necessary rigidity. This process overcomes the limitations of conventional manufacturing methods, generating technically precise components without wasting material. The technology facilitates testing and modifying designs quickly during the development phase and manufacturing only what is needed, accelerating the entire engineering cycle.
Key advantages of additive manufacturing in this project:- Create complex geometries, such as housings for the eighteen rotors, which would otherwise be difficult or costly.
- Reduce the total weight of the aircraft, directly impacting its flight autonomy and energy efficiency.
- Speed up the development process by allowing rapid iteration and on-demand manufacturing.
3D printing deposits material only where needed, consolidating multiple parts into one and reducing assemblies.
Advanced Materials for Demanding Flight Conditions
For aerospace applications, advanced materials such as carbon fiber-reinforced polymers or other special composites are chosen. These materials must withstand structural loads, vibrations, and environmental changes, all while maintaining a minimum weight. 3D printing enables consolidating multiple components into a monolithic unit, reducing the number of joints and potential failure points in the system.
Characteristics of the materials used:- High mechanical strength to withstand loads and vibrations during flight.
- Minimum weight, essential for maximizing the efficiency of the electric vehicle.
- Ability to be processed via 3D printing, allowing integrated and optimized designs.
Considerations for the Future and Maintenance
Although the promise of these vehicles is to avoid ground traffic congestion, their continuous operation presents new challenges. One aspect to consider is maintenance and spare parts logistics. The on-demand manufacturing philosophy means that, for some repairs, it may be necessary to wait for specific replacement parts to be printed, rather than having them stored in a traditional inventory. This redefines supply chain paradigms in urban aviation. ⚙️