{"id":4449,"date":"2022-10-18T08:16:58","date_gmt":"2022-10-18T06:16:58","guid":{"rendered":"https:\/\/am-hub.dk\/cases\/3d-printed-design-enables-a-drone-to-fly-longer-and-lift-heavier-loads\/"},"modified":"2026-09-02T13:13:13","modified_gmt":"2026-09-02T11:13:13","slug":"3d-printed-design-enables-a-drone-to-fly-longer-and-lift-heavier-loads","status":"publish","type":"cases","link":"https:\/\/am-hub.dk\/en\/cases\/3d-printed-design-enables-a-drone-to-fly-longer-and-lift-heavier-loads\/","title":{"rendered":"3D-printed design enables a drone to fly longer and lift heavier loads"},"content":{"rendered":"
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3D-printed design enables a drone to fly longer and lift heavier loads<\/h1>\n<\/div><\/div>\r\n\r\n

80% reduction in material usage through 3D-print design optimisation<\/span><\/p>\n<\/div><\/div>\r\n<\/div>\r\n<\/div>\r\n<\/div>\r\n\r\n

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The Danish startup Airflight tested metal 3D printing in the design optimisation programme Design for Additive Manufacturing (DfAM), where they succeeded in reducing the weight by as much as 67% on a lightweight bracket for the wings of their cargo drone.<\/p>\n

In the video, you can hear more about Airflight\u2019s optimisation work from owner and CEO Mikkel K\u00e6rsgaard S\u00f8rensen \u2013 and, not least, see the drone in the air.<\/p>\n<\/div><\/div>\r\n<\/div>\r\n<\/div>\r\n\r\n

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The case: Overview and context<\/h3>\n<\/div><\/div>\r\n\r\n

Airflight<\/a> <\/span>is based in Br\u00f8nderslev, from where they build some of the world\u2019s largest multirotors \u2013 essentially an oversized drone \u2013 to fly components and tools for the wind turbine industry. The largest drone has eight arms and can lift up to 200 kg. <\/p>\n

The company chose to take part in the 3D-print design optimisation programme DfAM to explore the possibilities for the brackets that hold the drone\u2019s arms. In the project, the brackets were design-optimised for 3D printing so they became lighter while still being able to withstand the loads-and they were also 3D printed in titanium. This resulted in a weight reduction of 67%-or a full 11 kg per drone. <\/p>\n<\/div><\/div>\r\n<\/div>\r\n\r\n

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\u201cThrough the project, we have achieved an 11 kg weight reduction and reduced the amount of material by 80%. The value for us is the extreme design flexibility, where we can achieve a higher strength-to-weight ratio, which is an important part of aviation, as it means we can fly for longer or with a heavier payload.\u201d<\/span><\/p>\n<\/div><\/div>\r\n<\/div>\r\n\r\n

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Mikkel K\u00e6rsgaard S\u00f8rensen<\/strong>
Owner and CEO
Airflight <\/span><\/p>\n<\/div><\/div>\r\n<\/div>\r\n<\/div>\r\n\r\n

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Results from programmes with Dansk AM Hub<\/h3>\n<\/div><\/div>\r\n\r\n