Project context

Within my company SkyQ, I explored the production of custom drone parts by creating a mold for drone arms. This project served both as a functional prototype and as a practice run for future composite manufacturing, particularly in carbon fiber.

Approach

Using the IPO design process, I designed and 3D printed a mold to produce drone arms. The goal was to test the feasibility of making lightweight yet strong components using forged carbon fiber. The process allowed me to experiment with molding techniques and material behavior, laying the groundwork for future production methods.

Tools & Techniques

• IPO design process

• CAD modeling

• 3D printed molds

• Forged carbon fiber prototyping

Outcome

Reflection

The result was a forged carbon drone arm, produced using a custom 3D-printed mold. This prototype validated the approach and provided practical insights into composite production for drone components.

This project gave me valuable experience in composite manufacturing techniques and mold-making. It also strengthened my understanding of how to design and test parts for lightweight, high-performance drones knowledge I will apply to future SkyQ projects.

Gallery

A visual impression of the project.