How Composite Materials Improve Drone Flight Performance and Durability

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Drones are fundamentally changing aviation. From aerial photography to commercial deliveries and infrastructure inspections, a new army of drones is taking to the skies to do things that were never possible. Drones are even applicable in the defense and emergency response sectors. They owe their success to advanced composites and aircraft composite technologies.

Drones must be simultaneously lightweight and incredibly strong. Advanced composites are what make both possible. Those designed specifically for drones must account for the unique needs these aircraft represent. Materials like carbon fiber reinforced polymers (CFRP) and fiberglass work extremely well for drone design. They provide a firm foundation on which drones are built.

Balancing Weight and Endurance

The single biggest factor in designing a new drone is its overall weight. Every ounce added to an airframe translates into more energy required to get it off the ground. And the heavier the material, the more energy a drone uses to remain aloft. That translates to reduced air time as weight goes up.

Excellent Strength-to-Weight Ratios

Advanced composites are fit for service because they offer excellent strength-to-weight ratios. Fiberglass and carbon fiber are significantly lighter than aluminum and steel. At the same time, they are mechanically stronger. By building a drone with advanced composites, you get:

• Extended Flight Times – Reducing a drone’s structural mass translates into more efficient use of battery power. Flights last longer.
• Increased Payloads – Lighter airframes are capable of carrying heavier payloads without increased energy consumption. Every ounce removed from the airframe is an ounce that can be added to the payload.
• Better Aerodynamics – Second to weight in terms of importance is a drone’s aerodynamic properties. Working with advanced composites allows for tremendous design freedom. Air frames and parts can be molded to match virtually any aerodynamic design.

Better aerodynamics means a more efficient flight. They lend themselves to better flight control and precision handling.

Aircraft Composite Technologies Built to Last

Advanced composites are extremely durable. They are built to last because they resist the stresses and environmental factors associated with flight. That is critical, especially when drones are being operated in challenging and unpredictable environments.

Fatigue, Impact, and Corrosion Resistance

So, what types of stresses are aircraft composite technologies capable of resisting? Here are the three big ones:

• Fatigue – Fatigue is a serious problem for all types of aircraft, drones included. Drones are especially susceptible because of their high-cyclic use cases. Advanced composites resist fatigue to reduce micro-cracking and degradation more effectively than metal materials.
• Corrosion – Advanced composite materials do not corrode. The materials offer a definitive advantage when operating aircraft in coastal areas and other wet, salty environments. Corrosion resistance also gives composites an edge in chemically harsh industrial environments.
• Impact – Impact energy and shock can be devastating to drone airframes. But using advanced composites engineered with aramid or carbon fibers can make an airframe capable of withstanding significant impact energy.

Because advanced composites are so resistant to the many stresses of flight, they are ideal for both airframes and the systems that protect batteries, motors, cameras, and other components.

Drone technology has a bright future. The more we learn about engineering them, the more capable they become. From our point of view, the best way to continue expanding drone capabilities is to simultaneously continue developing advanced composites and aircraft composite technologies.

Aerodine is a composites specialist. Our team could not be more thrilled to contribute to the development of advanced composites that are pushing drone technology to new heights. Next time you see a drone in flight, remember that advanced composites are what make it all possible.