At the start of the project, we produced presentation slides giving an overview of the manufacturing technologies relevant to drone production. We also reviewed the material parameters and sizing strategies required for finite element modelling of composite structures. Based on the information gathered, we have developed a pilot design, collected relevant standards and prepared test specifications. As with composite manufacturing, we started by designing capability tests for 3D printing technologies by preparing a technology overview. We gathered materials and manufacturing technologies that could be used for drone components, with a view to having as wide a palette as possible by the end of the project. For both thermoplastic and thermosetting pure polymer printing technologies, as well as for composite printing technologies, we collected the parameter ranges required for printing, as well as the parameters to be defined for subsequent design and material modeling. A test plan was drawn up and the available measuring instruments and competences were assessed. To define material models, we first reviewed the types of material behaviour of polymers and their composites. We reviewed the critical fibre lengths that a reinforcing material must have to achieve the appropriate composite behaviour for each processable matrix material. To set up material models, we reviewed the orientations at which different material behaviour can be expected for different printing technologies. For the parameter determinations, test specimens were prepared for mechanical purposes for tensile, flexural, impact bending tests and hardness measurements. The fatigue properties are to be obtained by tensile fatigue tests. The static and dynamic mechanical properties of the selected materials were determined for the material models. The fatigue tests have been started.

Failure of composite specimens printed with Markforged printer from ONYX CF GF and Kevlar materials during tensile testing