3D Printed and Topology Optimized Drone!

With today's incredibly easy access to technology, inspiring new concepts are possible! We combine the latest simulation technology, known as 'topology optimization,' with powder bed 3D printing and freely available drone hardware and software.
The resulting tricopter is inspired by the 'Orca' VTOL design from the 1995 computer game 'Command and Conquer' and features a unique, bionic design, acting as a proof of concept. A VDI webinar was also held to show the more technical details of the development process (German speaking). You will find the link here when available.
The interesting aspect is that the technology is versatile and can be adapted not only to the development of drones but also to heavy machinery, customer-tailored bike parts or even art, depending on one's needs.
The future is going to be exciting!
TIMESTAMPS:
00:00 Introduction
00:12 Project Inspiration - Command and Conquer
00:54 Topology Optimization
01:25 Thanks for these Simulation Tools
01:43 Drone Design Development
03:16 Interlude
03:43 Design Rendering
04:42 3D print
05:38 Flight
07:05 Outlook
07:18 End Credits
Software used:
Altair Inspire (Preperation, Topology Optimization, CAD creation, static loads)
Altair Inspire Studio (Rendering)
Altair Hyperworks (Result evaluation)
Licenses: Check "web.altair.com/altair-student...".
Link assumed by me, for details contact Altair.
BetaFlight ( FC)
DaVinci Resolve (Video Editing)
Parts:
GEMFAN D76
GEMFAN Hurricane 2023
BETAFPV 2004 3000K
BETAFPV 1204 5000KV
Mamba F405 MK2
BetaFPV 4S75C 850mAh
FRSKY ~R6
Servo: MEX 65MG
850mAh, 4S LiPo
Bearing: 25/20/4mm, 21,15,4mm
FPV equip. prepared but not activated.
I really feel honoured by your interest in the STL files and the frame kit! I haven't shared them yet because the current design is in the prototype stage. While it works great, it requires a lot of initial tuning and will likely cause some educational crashes in the process. When I share the STL files or sell a kit in the future, the quality will be high enough to ensure you have a great experience with it! I'll keep you updated as the plans crystallize!

[@rainday1518]

GIIIIIIIVVVVEEEEE MMMEEEEE TTHHHHEEEEE STL !!!!!!!!!!

[@bobbymccourt6794]

Hell I’d pay for them!

[@Maisonier]

@@bobbymccourt6794 I'd Buy That For a Dollar 🤖

[@hanzrudel6486]

Puedes diseñarlo tu mismo, usa un inventor generative model, está herramienta en base a los parámetros que tu estipules puede generar formas orgánicas que optimicen el peo o la resistencia. Debes hacer unos cuantos cálculos y definir las restricciones y listo. Tienes un modelo optimizado listo para imprimir o fabricar mediante algún proceso definido.

[@hanzrudel6486]

​@@bobbymccourt6794si te sirve se podría hacer un grupo para diseñar y generar el modelo. Se puede lograr mediante inventor o solid works

[@jupiterbjy]

This is the most lore-accurate one I ever seen. So many forget about horizontal tail fan that does the pitching.

[@coolcat312]

Very cool. C&C has always been one of my favorite games.

[@DanMeyerMeisterTek]

Wow this is awesome! The final tricopter looks like it flies very well! I am looking forward to more details!

[@kiddfpv]

This is so much more impressive that most people will understand, like to get that thing to actually FLY and fly that well is incredible!!

[@bibeksah4953]

The design, process and visualization of this project is amazing and cool

[@MrFunnyDad2024]

Thats just outstanding. Guy in his shop making "Gaint step for Mankind" kind of break thru. Also - There's a call for you... Its the US DARPA Military Think Tank...

[@Nyerguds]

It's interesting that the Orca seems to angle forward when going faster, because that's exactly how it acts in the original game; in fact the craft has two sprite sets in the game, a flat one and a forward-angled one. (For the record, all vehicle sprite sets are typically 32 prerendered frames to get a full 360° rotation)

[@blacksto1]

Also looks like a Hunter Killer from Terminator. Very nice project!

[@heidi5942]

Very cool project. I haven't seen much of this generative structures, so that was awesome to see. But please turn down or off the music when talking, it's rather distracting.

[@powerofn2858]

That was also one reason for starting the project. Not enough good topology optimization videos out there. Thanks for noting on the volume.

[@CopperHvH]

This is an awesome video. I wouldn’t have thought this came from a channel with less than a thousand subs

[@Makex_sweden]

This makes me even more exited for the future. It's ironic how a design like this makes fans feel outdated. Image this design with silent ionic thrusters or something. that would be dope.

[@costantinoskitsios]

I'm amazed by such a great design, also the rendering is perfect, with textures and all the components that the model needs. Thanks for the inspiration!

[@daan3898]

Skynet had the same idea.

[@raulglez]

An autentic 'Hunter-Killer'.

[@raptorflyaboya]

I've always wanted to make an Orca. Well done!

[@AerialWaviator]

Such a fascinating design, and design process. That the drone was able to meet weight, plus rigidity constraints and it flew quite well, is very impressive! Would like to see more details of topology optimization design process used in a future video. A simple design, to focus on tools used and the design process. Have seen discussions/graphics of topology optimization designs, but never applied to creating actual working object(s).

[@stephenrider6107]

this gives me some very geeky ideas. You ROCK!

[@Clark-Mills]

Nice explanation and demo, great work, thank you.

[@spikeydapikey1483]

Amazing! Well done!

[@sam19698487]

I can't wait to buy a kit. Great job.

[@patrickkoller3181]

Incredible of what modern simulation software is capable of already and awesome that he really build it, looking forward to the 2nd loop.

[@bannanepotter9562]

It is a very interesting thing !

[@thomaskitzler3454]

Cool stuff 🎉

[@Termuellinator]

Looks really cool, awesome job!

[@swaggythecat]

Very cool dude. Excited to see what you do next!

[@KaliKavala]

Woah, great project :)

[@aidandodds7672]

This is actually amazing!

[@cadcaetutorial2039]

So perfect sir

[@DirkLarien]

Awesome ! The flight part is perfect with act on instinct in background :-)

[@austinshupe9626]

Reminds me of some of monophans works. Awesome project!

[@achroma3040]

That is fantastic!! Keep it up!

[@deplorablesecuritydevices]

This made me really happy.

[@shawnhollahan590]

Excellent Post. More like this and you'll have hundreds of thousands of followers.

[@weirdsciencetv4999]

Amazing work!! Subscribed!

[@FiglioBastardo]

#metoo 😂

[@muratarabaci05]

Good Job! Bravo!

[@andrewwatts1997]

That looks amazing !!

[@Maisonier]

Great video! liked and subscribed.

[@geerdjacobs6484]

I love C&C. And now take my money for the frame kit :)

[@smallpeople172]

+1 for the orca

[@brucemangy]

This orca was awesome to pilot in C&C renegade :) awesome work :)

[@thewatersavior]

I hope the updated version gets flip out wings and a go fast mode. Awesome!

[@PiDsPagePrototypes]

Process is real smart. Final vehicle looks a little underpowered, but the design should be able to adapt and adjust for that nicely through ongoing itterative fine tuning.

[@evlsc400]

Wow! ‘Engineering!‘ - RA2

[@aaronescorza3634]

just what I was looking for some time ago

[@KamikazeMedias]

GIIIIVEEEEE MMEEEEEEEE THEEEEEEE SSSSTTTCCCC!

[@powerzox8326]

Very cool!

[@cadcaetutorial2039]

So weldon this lecture sir

[@Shampoo1014]

Holy crap you literally brought a piece of my childhood to life. Are you planning on sharing/selling the files at all?

[@dewaynehiggs2098]

That's amazing!

[@taumelscheibe5948]

Absolutely amazing! I´ve always wanted to build an RC Orca myself but that project never went past the static display phase (files can be found thingiverse if anyone wants to have a scale model). Would be really interesting to know how much extra weight can be added before the flight characteristics become worse.

[@stefanguiton]

Great video

[@sergeigen1]

omg this is amazing

[@OxKing]

Now do an orca helipad with LEDs in it. and make it wireless charge that thing. 😎

[@Stormrider-Flight]

shut up and take my money

[@BioClone]

Shit, that actually could fit perfectly

[@powerofn2858]

:D And the helipad must unfold itself! No, really, someone build that thing and let me know the Parts and interfaces I need to implement so it charges!

[@smellycat249]

This is amazing

[@PathosBedlam]

Printed in carbon fiber nylon this would be nearly indestructible. Please let the 3D printers of the world play with this design and improve upon it. Only by freeing the data can we all improve the world together.

[@chrishechtl8330]

Very cool! It reminds me of the HK flying craft from the Terminator series too.

[@MatejPranjicOfficial]

Cool !

[@spactorexe5780]

Thats sick dude!

[@mdiqbal8747]

You should make more projects like this one. This is very cool looking designe. subscribed

[@Christoph_Hofmann]

Great Project !. What kind of software is runnig on the FC ? ArduPilot, INAV or something else ?

[@powerofn2858]

BetaFlight. A little tricky to use as it assumes the rear rotor can tilt. Hower it still does a splendid job and people provide it for free!

[@DragonyEstorial]

i am in Love! the movement is like the ingame , the Orca is my Favorite Unit of the GDI xD *Start instll cnc remstered*

[@Freedom-Engineering]

Flash back to my 90s childhood lol. You guys releasing STL files for the Orca? great work

[@georgskleinewerkstatt8678]

😮 wie geil ist das denn?

[@user-nl8tm8jl8l]

this topology is inspiring

[@sonofagun1037]

Now I want more

[@sygad1]

I think i've just seen the origin story of the HK units ;-).....awesome work BTW

[@maryjane136]

Beeindruckend. Video von der Kamera wäre interessant.

[@BioClone]

Oh god the technology of peace. I dreamed on building a RC orca many, many times I love the whole VTOL concept and the ORCA is really unique, I love the fact that on your make it feels really like a fighter, moving easily forward and not howering that much like many other similar builds looks moves moslty like quadracopters. It really feels unique *note, please add a couple leds on the sides and some kind of flashlight to the front would feel awesome

[@babbagebrassworks4278]

Well done. Recently got a 3D resin printer for model train, started printing gears and soon gear boxes. But it got me thinking, robotics. I really hate the current generation of subtractive machined ugly bots. I was thinking about AI generated skeletons and lightweight materials. Warzone2100 is my current game, not just because it has "AI" that can be modded. You have a new sub.

[@EnterpriseKnight]

Oh shit, It actually flies

[@raffizmc]

I like this

[@RexAnothership]

Too cool

[@pilotmiami1]

BRAVO.

[@safiamunir5046]

amazing, i also hav a design in mind which i would like to bring to life.

[@pshellien]

Epic

[@pathfinder.george]

Dude!! The Orca was such an inspiration since childhood! This is insanely awesome. Can we buy the STL? I want to print it for my desk.

[@hazza64]

I've always wanted to make a drone based on the Orca (Tiberian Dawn version). It looks like you're flying as a tri-copter (can't be sure); are you looking into doing thrust-vectoring control for forwards flight?

[@constipatedmushroom9837]

I've been trying to create simple topology optimized structures for bicycles for forever and fusion 360 hasn't worked at all, ill check out Altair hopefully they are more intuitive!

[@AlexRoe]

Very cool! So when are you going to build a much larger scale version?

[@Skott62]

You know whnen I see videos of these type of design and builds it makes me wonder if the U.S. Military has made any prototypes like this? The concept and designs on these small scale products work but what about large full scale? I realize the cost would be enormous due to all the mechanical and electronics involved but I keep wondering if we'll see these in real life? Anyway great video. Thoroughly enjoyed it. Can't wait to see more.

[@ernie5229]

Full-scale model next!

[@gordonpromish9218]

interesting how closely it resembles an aerial hunter-killer from the 1984 Terminator

[@iwh7]

Realy nice, do you plan on releasing the 3d printing files?

[@CrustiestGuide4]

Cool Vid! It's insane how far we have come manufacturing and modelling wise. How did you smooth out the topology optimised structures? Did you remodel the parts?

[@powerofn2858]

In the Software (Inspire), there is a feature called "Polynurbs". It is perfect to transfer topology optimization results into a clean CAD. With a standard CAD programm, I would surely have gone nuts ;)

[@kingrutse3278]

Need to submit the design to darpa this is better than what they working on 😂😂

[@rav3n595]

You may be able to solve the 'pitching forward' issue, by using a reverse thruster assembly on the rear duct. It will allow some of the air to be directed upwards, preventing the tail from lifting, which has always been a problem with VTOL craft.

[@danieldewindt3919]

Grate that looks awsome. Where did you share te files? Nice video. I like drawing in Autodek Inventor myself

[@ludovicpavesi2540]

well done, which software did you use for the optimization ?

[@powerofn2858]

Thank you! I used Altair Inspire. In the background, the program runs Altairs Optistruct solver.

[@spearhead30]

This is what the terminators flew.

[@helipilotuh1]

You should try printing props with unevenly spaced blades, maybe it will quiet it down, see Airbus helicopter fenestrons.

[@michaelthompson8251]

tutorials. using open source solutions. would be worth subscribing to. but what you did was really cool

[@ThantiK]

So do you plan on sharing the files so others can replicate your work?

[@powerofn2858]

Thanks for asking :) It's a prototype and also needs some special FC tuning, so sharing it with good quality needs more preparation. I currently focus on developing the next model. If many people want an Orc though, there will be a way!

[@DIYdood]

Amazing work! Can you please let me know what software you used for the topology optimisation? I've seen there is an add-on for FreeCad but I don't think it is stable for the latest versions. Thanks!

[@powerofn2858]

Thanks! I used Altair Inspire. It can also handle the CAD creation, worked pretty well for me. They usually give away free licenese for students, just contact them.

[@rolliseventeen]

sieht gut aus und da kann man wirklich noch viel optimieren. Wenn es unbedingt ducts sein müssen würd ich eher auf 5-6 Zoll gehen. Die Flugzeiten sind dann etwa besser. Ducts fressen mindestens 20% vom Schub, bei kleinen mehr, bei den größeren weniger. Eigentlich will man gar keine ducts, das will nur das Marketing wegen der Optik.

[@thecreativecave]

That is awesome, now to plan a production version for us all to buy?

[@TansuOzcelebi]

wow

[@tristanwegner]

Are there ways to take the print direction into account for the topology optimization? Because such anisotropic materials that delayer easier, you would expect different optimal thicknesses in different directions.

[@powerofn2858]

Good question. I assumed isotrope behavior, which should have been nearly correct for Multijet Fusion PA12. Turned out it wasn´t, too brittle on impact, maybe because of anisotropy. Current solution is to use PA11, which is way more ductile! Until now, anisotropy seems no big issue with that material.

[@MrJay_White]

interested in how you set up the controls. how does it know the angle to turn the thrust pods etc.

[@JustAnotherBigby]

Wow. I'm blown away. This thing is art. Are the models for this available anywhere? Can you give an order of magnitude hint at what the printing costs were? If the models stay private, are you considering of a small commercial run? I'd love to have one of these. [ or v2. ;) ] On the topic of weight optimization, i think your fan shrouds don't need the bell-mouth on the bottom side...

[@powerofn2858]

Thanks for asking :) Small Comercial run is an option but would currently slow the development of the next design. Shower, if many people want that, go a find a way! The price for printing is middle/high 3 digits due to the size. There's a lot of potential for mass down/cost down.

[@paulriggs42]

An awesome project and outcome…. Would love to know your process…. 5 yrs ago I used Hyperworks software with modefrontier and HEEDS to do similar optimisation but the managers are Ford didn’t embrace it as their only focus was cost reduction and not weight/performance improvements…