Case Study: University of Warwick achieves large-format, lightweight search-and-rescue UAV production with 3D Platform

UW Warwick Uses 3D Platform’s Printer for Humanitarian Project

The University of Warwick engineering team, working with industry partner GKN Aerospace and students in the Horizon (AM) program, set out to design a humanitarian UAV capable of delivering emergency supplies to hard-to-reach locations such as mountain rescue sites. The challenge was to produce a lightweight, large-span airframe (7-foot wingspan) with a ~5 kg payload and 80 km range while minimizing assembly fittings and achieving aerodynamic stability without a stabilizing tail.

Using 3D Platform’s WorkSeries large-format printer, the team printed full mold masters in one piece—eliminating heavy fasteners, enabling a larger wingspan for more lift, and reducing weight. Engineers used Autodesk Fusion 360 and Netfabb to optimize geometry and printability; about one month of continuous printing produced reusable molds for resin-infused carbon-fiber layups. The result is a flight-capable, multifunctional prototype developed in collaboration with industry that demonstrates reduced part count, improved performance, hands-on student learning, and potential future commercialization.

University of Warwick

Simon Leigh

Associate Professor of Engineering