In the previous article, we discussed the nine key points of high-efficiency lightweight injection molding for drones. This article will delve into the three core elements of material selection, design optimization, and injection molding process, explaining why they are crucial for drone lightweight design.

Material Selection: The Foundation of Lightweight Design

Material selection is the cornerstone of drone lightweight design. According to the report of the Materials Research Society (MRS), high-strength and lightweight plastic materials stand out due to their excellent properties. Carbon fiber reinforced plastics (CFRP), with its extremely high strength-to-weight ratio, significantly enhances the rigidity of the material while greatly reducing the weight, making it the preferred material. Glass fiber reinforced plastics (GFRP) also performs well and has a relatively low cost, suitable for cost-sensitive projects.

High-performance polymers such as polyetheretherketone (PEEK) and polyphenylene sulfide (PPS) are also favored for their outstanding properties. As shown in the research data of the Journal of Materials Science and Engineering, the tensile strength of PEEK material is as high as 90 - 100MPa, and the density is only 1.3 - 1.4g/cm³. Moreover, it has excellent high-temperature resistance and is suitable for drone components working in high-temperature environments. The PPS material is excellent in chemical stability and flame retardancy and performs well in complex chemical environments and scenarios with high fire protection requirements. These materials provide a solid foundation for drone lightweight design, and manufacturers can make a reasonable selection according to the specific requirements and cost budgets of drones.

Design Optimization: The Core of Achieving Lightweight Design

Design optimization is the core link in achieving drone lightweight design. Topology optimization technology utilizes advanced computer simulation software and is based on the finite element analysis principle to accurately determine the optimal distribution of materials in the drone structure. By simulating various loading conditions, such as aerodynamic loads and impact loads, the minimization of material usage is achieved while meeting the requirements of strength and stiffness. For example, according to the drone design case of NASA, the topology optimization technology reduced the weight of the wing by 15% while maintaining the structural integrity and flight performance.

During the design process, the integration of functions is also of great importance. Integrating multiple functional components into a single whole not only reduces the number of parts and the complexity of assembly but also further realizes lightweight design by reducing the weight of connecting components. For example, the integrated design of the landing gear and the fuselage structure can not only improve the structural strength but also effectively reduce the overall weight.

Injection Molding Process: The Key to Ensuring the Quality of Components

Precision injection molding technology is the key to ensuring the quality of drone components. This technology requires precise control of various parameters in the injection molding process, including injection pressure, speed, and temperature. According to the industry standard ISO 294 - 1:2017, precise parameter settings can ensure that the dimensional accuracy of the parts is within ±0.1mm, and the surface roughness is lower than Ra0.8μm, thus greatly reducing the subsequent processing procedures and improving production efficiency.

Multi-component injection molding technology provides an efficient solution for manufacturing complex parts. It can perfectly combine different materials in a single operation to form components with multiple functions. For example, in the manufacturing of the drone shell, by using the multi-component injection molding technology to combine the wear-resistant outer layer material with the shock-absorbing inner layer material, both the wear resistance of the shell and the protection of the internal electronic equipment are enhanced.

In conclusion, material selection, design optimization, and injection molding process are the three indispensable key points for high-efficiency lightweight injection molding of drones. They are interdependent and work together to provide a solid foundation for the lightweight and high-performance design of drones. By continuously optimizing these key points, drone manufacturers can improve production efficiency, reduce costs, and manufacture lighter, stronger, and more durable drones.

Worldbound Group, a custom service provider of precision injection molded parts for mid-to-high-end brands for more than 20 years, has successively obtained the titles of transformation and upgrading demonstration enterprise and national high-tech enterprise. It not only has 5 injection molding processing factories in Vietnam but also has 7 factories in Dongguan, Guangzhou, and other places in China, providing a full range of one-stop plastic and metal processing and customization services.