Engel Implements Fully Automated Production Of Drone Composite Rotor Blades

The core of this manufacturing process lies in a structural sandwich design composed of carbon fiber-reinforced thermoplastic unidirectional tapes and injection-molded short-fiber composite materials. The unidirectional tapes form the load-bearing outer layer of the rotor blades, precisely positioned into the mold and secured via vacuum to ensure the reinforcement fibers are strictly aligned along the load direction. Material is used only where structurally required, achieving efficient material utilization while balancing lightweight design and structural strength.

In subsequent processes, short-fiber thermoplastic core material is injected between pre-placed unidirectional tapes and tightly bonded to the outer layers, forming a near-net-shape component structure. To further enhance lightweighting potential, the core material employs a chemical foaming process, effectively reducing component weight without compromising the structural performance of the rotor blade, thereby improving the drone’s endurance.

The final molded rotor blade integrates lightweight and high durability, with molding, structural functions, and material bonding completed in a single automated process. After the specified final finishing, the components can be directly put into use.