Flapper Drone

Client: Flapper Drones

2020

In market

About Flapper Drones

Flapper Drones is a company that spun-off the Delft University of Technology. They develop, manufacture and sell winged flying robots for research, drone shows and other creative applications. They additionally make DIY kits for people to build their flapper drones. Their drones fly without propellers instead flying by flapping their wings. Their drone platforms are customizable, easy to service and capable of being autonomously operated.

Early Flapper Drone concept shown here with the earliest aesthetic shell concept.

The early Flapper Drone shell concept was made using Multi-Jet Fusion.

Aesthetics & manufacturing

At Flapper Drones, I had 2 responsibilities, designing a new set of shells and attachments that could be attached to the central mechanical unit and the “spine” and, to research and finalize an alternate manufacturing method for the shell designs.

Inspiration was derived from flying animals as forms evolved naturally.

One of the inspirations was an angel, making it feel appealing in drone shows for kids.

Testing with Prototypes

A big part of the process was 3D printing and testing the shells to check their look. Even more important was to print and test the attachment systems for the shell and spine.

Testing the final curved look of the shells with some "at-home" vacuum forming.

Attachment systems as conceptualized in CAD and then 3D printed for testing.

Manufacturing

Due to the desire for low to mid quantity manufacturing, numerous vacuum-forming options were explored, along with continued communication with manufacturers in the Netherlands. After multiple tests with Polycarbonate, 3D-printed PETG moulds, burnt and warped moulds and forms, the decision to move to 3D printing was made.