Flying-Cam UAS Built by Additive Manufacturing

FLYING-CAM, a developer of rotary wing Light Unmanned Aircraft Systems, has partnered with Modena, Italy based CRP Group, a leader in laser sintering technology and well-known for their Additive Manufacturing materials called Windform, to construct a Special Aerial Response Automatic Helicopter: SARAH.

Belgium based FLYING-CAM ignited the close range aerial filming concept in the 1970s and has been leading the way with its Award-winning Flying-Cam II in the motion picture industry. Its clients includes: Harry Potter, James Bond, Mission Impossible, Red Cliff and many others. Since 7 years FLYING-CAM has focused on the development of the next generation Rotary Wing light UAS.

SARAH has reached production stage. The Spanish Aerospace Research Centre FADA-CATEC has taken delivery of its first SARAH systems. They are used for air traffic management and general aviation research, technology & development projects in partnership with BOEING, EADS and AIRBUS MILITARY. Two weeks training was sufficient for the Client to take control of the whole system.

FLYING-CAM dedication is to design field proven state-of-the-art products. Each SARAH System is with the KISS & JEEP concepts as a goal: Keep It Simple Stupid and Just Enough Essential Parts.

As a Light UAS, 25 Kg TOW including payload, SARAH is recognized to be the most advanced technology available today: easy to use, maintenance free propulsion, innovative FLYING-CAM proprietary Automatic Pilot System and most importantly the best real time image quality, Day or Night.

The first Flying-Cam Airframe Structure was made with composite moulded material. FLYING-CAM moved to SLS technology in collaboration with CRP Technology. The requirements were fast iteration process, best ratio between structural strength and weight, acceptable consistent result and opportunity to combine multiples functionalities from one unique part.

Using SLS technology CRP is able to provide fast response time to new requirements and improve manufacturing time and facilitate production in series. Alongside it allows easier customization of the platform.

Main Flying-Cam parts using Additive Manufacturing and the Windform materials are:

• Airframe structure
• Air guide cooling system
• Tail unit
• Main battery connection

SARAH supersedes heavier and more costly systems. Moreover, the 25 Kg category regulation is less demanding than for heavier platform which further reduces the operating costs. Its applications include Emergency Management, Surveillance, Defence, ENG & EFP Broadcast TV and Motion Picture Production

Source: 3Ders.org