Acodyne, a Danish company specializing in cargo drones capable of carrying up to 200 kg, has successfully reduced the weight of its drone blades by 30% through metal 3D printing. This collaboration with the Danish Technological Institute (DTI) in a MADE demonstration project has not only lightened the load but also improved the overall performance and competitiveness of Acodyne's products.

Claes Nicolajsen, CTO at Acodyne, stated, "With metal 3D printing, we have reduced the weight of the blades by 30%, which can lead to an overall weight saving of 1-2 kg on the motor’s fan disk, improving both the speed and response time of our products and giving us a significant competitive advantage." The weight reduction was achieved by redesigning the blades to be hollow and adding internal ribs, all while maintaining their structural integrity. The blades were printed in titanium, a material known for its lightness and strength.

Mads Schnack, CEO at Acodyne, explained that traditional manufacturing methods would have made such a design challenging. "3D printing allowed us to implement a design that would have been difficult to manufacture using traditional methods. The result is a lighter component that can still withstand the forces it is subjected to at high speeds." This new design not only reduces the weight but also improves durability and uniformity.

The new blades are approximately one-third of the original weight, saving up to one kilogram per engine. This reduction in weight leads to reduced energy consumption and faster acceleration. Additionally, creating new 3D designs and manufacturing the blades is simpler compared to traditional methods. The new blades also exhibit superior uniformity in both weight and geometry, making them easier to repair.

Claes Nicolajsen further noted that despite the slightly higher unit price compared to Acodyne's old blades, "Considering the cascading effects, we expect to be close to break-even. We may have already achieved a gain." The benefits include faster speed and quicker reaction time for flying objects like drones and planes.