Lightweight Components for High-Altitude Utility Drones
Successfully producing small-batch, multi-variant components for industrial drones — including stable fabrication of 0.8 mm thin-walled AlSi10Mg parts that reduce weight and lower costs.
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Product
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High-Altitude Utility Drones
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Industry |
Power Utilities |
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Technology |
3D Printing + CNC Machining |
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Material |
Aluminium Alloy (AlSi10Mg) |
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Stage |
Prototype testing |
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Surface Treatment |
As-machining |
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Why Choose Us |
High Cost-Effectiveness and Reliable Technology |
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Outcome |
Cost control and weight reduction without thicker walls. On-time delivery of multiple drone components |
Background
In this project, the partner (hereinafter referred to as Company A) is a pioneering enterprise leading the digitalisation of power networks, whose innovative technologies are accelerating the global grid’s transition towards digitalisation and intelligent operation.
To meet the demanding needs of high-altitude operations in power systems, Company A has developed a new type of utility drone.
The drone incorporates multiple structural components, many of which feature ultra-thin walls and complex internal cavities. In particular, some parts combine large dimensions with thin walls as slim as 0.8 mm. This is considered highly challenging and high-risk in the field of manufacturing.
Opportunities for Collaboration
During production, the extremely thin walls and complex cavities made it difficult for Company A to find a reliable supplier, as many struggled to ensure consistent quality.
When Company A approached XMake, their requirement was clear: no increase in wall thickness, and the part must remain lightweight. This added significant difficulty to the project.
Instead of backing down, our team conducted a rigorous process evaluation, assessed risks, and leveraged our supplier network to connect the client with experienced partners. After several refinements, the solution was approved, and the project advanced smoothly into implementation.
Challenges
The real challenge of this project lies in the manufacturing of the part itself. For example, in Company A’s drone program, a large housing component faced multiple challenges during production：
◆ Ultra-thin walls (0.8mm): Far below conventional design thicknesses, making warping and deformation highly likely during printing. This demands exact equipment parameters and process control.
◆ Large dimensions + extreme thinness: Maintaining flatness across such a large, thin surface is exceptionally difficult; residual stress release inevitably causes warping or corrugation.
◆ Post-processing challenge: Removing supports, heat treatment, or surface finishing can easily damage the part if not handled carefully.
Our Solutions
Facing these challenges, we explored multiple approaches—from process selection and material use to parameter optimization—to ensure parts could be produced exactly as required:
To meet the demand for lightweight, thin-walled parts, we selected AlSi10Mg and applied metal 3D printing. Through DFAM evaluation, we confirmed 0.8 mm as the stable printing wall thickness.
For large thin-walled parts, we optimize orientation, supports, and stress control—reducing material waste, preventing warping, and improving yield.
During production, our engineers fine-tuned critical dimensions based on manufacturing needs. For example, adjusting a hole diameter from 25.8 mm to 25 mm improved fit accuracy and ensured smooth post-machining.
Result
With our comprehensive manufacturing support, we successfully delivered complex components for Company A, helping them achieve their production goals：
Lightweight parts: Optimized support strategy and post-processing ensured thin yet strong components, stably produced without thickening.
High yield: First-pass yield reached 93–97%, batch yield ≥98%, with rework under 1%, guaranteeing consistent quality.
Fast turnaround: Small-batch lead time of just 2–3 weeks, keeping pace with R&D and production schedules.
Product Iteration Collaboration
Beyond the aforementioned technical practices, we also continuously assist Company A in product development and component manufacturing, providing specific support including:
✔ Efficiently delivering small-batch, multi-variety orders for up to 88 components, supporting prototyping, testing, and iteration needs.
✔ Advising on integrated molding solutions and wall thickness optimization, ensuring high yield while maintaining manufacturing flexibility.
Future
Within one year, Company A has already placed multiple repeat orders, proving the reliability of our high-quality manufacturing and professional support.Looking ahead, we will continue to strengthen our partnership. While the current parts remain in split design, both sides have reached consensus on an integrated solution, laying a solid foundation for future mass production.