Lightweight drone components for building and maintaining UAVs

Drones, UAVs and other unmanned flight systems are becoming an increasingly integral part of everyday life, from autonomous flying taxis to delivery drones transporting packages. These applications place demanding requirements on every component: low weight, reliable operation in all weather conditions and long service life are essential for safe and efficient flight.

Companies such as Babcock are now collaborating with technology companies to design and build autonomous counter-drone platforms and the Ministry of defence is encouraging UK suppliers to develop a low-cost interceptor, which will be developed to protect the UK from airborne threats.

But how do we cope with the challenges that come with manufacturing drones? How can companies reduce weight? How can they manufacture sustainably? All of these considerations need to be designed in and thought about.

igus® high‑performance polymer components are ideally suited to these challenges. They operate without additional lubrication, run quietly and remain completely corrosion‑free, making them perfect for lightweight aerial systems. In addition, many of our iglidur® materials meet the stringent FAR 25.853 fire protection standard, ensuring compliance with aviation safety regulations.

What is a UAV drone?

A UAV drone (Unmanned Aerial Vehicle), means the drone flies without a pilot, passengers or crew on board. These drones are either controlled remotely by an operator on the ground or completely independently using automation and technology. There are also drones that operate completely underwater; UUV (Unmanned underwater vehicles) such as submarine drones controlled remotely and pre-programmed.

How do drones work?

Power - provides energy to operate the drone
Propulsion- generates thrust to lift the drone
Flight- controls the stability in the air
Navigation- determines the location
Communication- exchange of data between operator and drone
Payload- equipment carried on flight

Different types of drones and UAV's

Multi-rotor drone

In order to be classed as a multi-rotor drone the drone needs at least 2 horizontal rotors. These are simple to construct, control and program so are popular drones in many applications.

Helicopter drone

A helicopter drone has a single spinning rotor in the centre of the drone, similar to manned helicopters.

Quad-coter drone

Quad-copter drones are UAV's with 4 individual motors and propellors. Traditionally the quadcopters have two clockwise spinning rotors and two anticlockwise. These tend to be relatively simple to program.

Underwater drone

Unmanned underwater vehicles (UUV's) are fully submersed uncrewed drones that operate under water and are becoming more and more popular. These can be remotely or autonomously operated.

What are the main challenges that arise when building a drone?

Lead time of components and the complexity of the frame design seem to be the main pain point for designers and hobbyists; with many customers noting a lack of modularity and ease of construction and deconstruction as a roadblock.

It used to be that buying from China was cheap but in recent years, not only has component cost gone up but the delivery costs to get parts in from China has sky rocketed while delivery time can be weeks.

This isn't a problem with igus parts. We hold a large stock of items in the UK and further stock in Germany. We also offer free delivery for all component parts ordered through the website.

Building a drone or conducting drone maintenance? We are here to answer your questions and support your project with expert advice and the right components.

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Key advantages of using our components for building a drone

FAR 25.853 compliant materials

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Tested in real UAV applications

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Corrosion resistant

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Cost-effective solutions

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Low noise and minimal vibration

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Lightweight aerospace solutions

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Fast project turnaround

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Predictable service life

Our components for building and maintaining drones: where they’re used and why

Components within drones/ UAV	Application	Benefit/ feature
Plain bearings	Folding and pivoting arms	Maintenance and lubrication-free, lightweight
Energy chains	Ideal for docking stations	Cable management, reliable, robust, flexible
Spherical bearings	Gimbals for cameras	Smooth operation
Leadscrews	Battery swapping	Accuracy, reliability
Linear guides	Inspection	Precise and accurate movement

Drone uses and successful applications

The use of drones in agriculture

Pest control drone

"FitoStinger" is a drone for pest control: an extendable arm can be brought very close to the infested area to spray a pesticide, for example. A drylin® linear guidance system is used to move the arm. igubal® bearings are used in the guide system of the transport tubes containing the pesticide and in the articulated arm. An energy chain from the E2 micro series is also used. The materials used have the required strength and rigidity for this application and are also extremely light.

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Drone use in construction industry

Drones are ideal for use in construction as they are used for aerial surveying across sites. This makes the whole process a lot safer than humans having to survey.

The drones are able to capture images and track progress across the site, reporting back to the management companies.

From a safety aspect, using drones for these types of sites surveys is a positive move for construction companies.

Drone in a box

With a drone in a box system, you can let drones fly automatically and autonomously. Typically, three components are necessary:

A drone that can be charged automatically, e.g. via charging contacts on the landing skids, a gear you attach to a normal drone or an automated battery replacement in the box.
The box serves as a platform for the drone to take off and land. It is designed in such a way that it can charge the drone or automatically replace the battery. During the charging process or when the drone is not meant to be in the air, the box is a secure repository.
Control software plans and controls flight applications and routes.

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Model aeroplane uses lightweight & corrosion-resistant flanged ball bearings

The Institute of Space Systems (IRS) is testing and demonstrating the use of a remote-controlled model aeroplane as a remote sensing platform. The model aeroplane "Stuttgarter Adler" is equipped with various payloads in order to carry out scientific missions to determine the "bidirectional reflectance distribution function" (BRDF) and to record environmental data. The "Stuttgart Eagle" was specially designed and constructed for its task by students from the Faculty of Aerospace Engineering. It differs from the model aeroplanes used by amateur pilots in that it takes safety-relevant factors into account. The design provides for a large fuselage for the instrumentation, and the electric drive system is housed in two engine nacelles in the supporting structure.

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Lightweight birotor drone

An igubal® spherical ball has been integrated into the swashplate of a reverse birotor drone. The special feature of the "FSS3 Drone" is that it is controlled by two helicopter rotors and the swashplate is attached directly to the mast. All components have to function at different temperatures, humidity and under heavy loads. The assembly of the spherical ball is innovative for several reasons: it is optimised for the weight level and uses only one component.

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Gas pipeline inspections using drones

Inspecting gas pipelines with helicopters is expensive, time-consuming and most of the time unnecessary. A German company, Exabotix has designed a drone fleet that automatically takes off on inspection flights and after the mission, the drones land in remote hangars that are maintenance-free thanks to our drylin W guide systems.

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Frequently asked questions

There are many components that make up a drone, including the frame, motors, propellers, speed control, battery, power distribution board, camera, bearings, slides and lead screws. Each component plays an important role in ensuring reliable flight and operation. To maximise performance and reliability, these components should be lightweight and weather-resistant to help ensure the drone's operation is not compromised.

A drone is manufactured through a process of mechanical assembly, electronic integration and software programming. Many drone components are produced using a range of manufacturing methods, including 3D printing, injection moulding and welding, before being assembled together. The software is then installed, and the drone is calibrated and tested.

While manufacturing methods vary by drone type, the same core stages generally apply.

UAV stands for unmanned aerial vehicle, another term for a drone. UAVs are an aircraft that operate without anyone on board.

It will depend on which bearings you are using. If they are igus bearings then they will not require oil or any kind of lubrication. If they are metal bearings they may need lubricating.

Drones are used in so many different applications and industries such as building inspection and cleaning, agricultural industry as crop damage assessment, deliveries, light shows, commercial use for photographs and in defence.

Drone maintenance is ensuring the drone is kept in good working order with regular inspections and services. It is essential that the drone is kept clean and up to date with maintenance inspections in order to keep it operational and legal.

It depends on the drone and where in the drone the bearings are being used. There are plain bearings, spherical bearings, and pivot bearings.