Metal additively manufactured drone blades cut weight by a third
March 13, 2025
The Danish Technological Institute has collaborated with Acodyne on a MADE project to optimise the fan blades of drone motors by reducing their weight. Acodyne’s cargo drones are large and fast, capable of carrying up to 200 kg. These drones are designed for customers in hard-to-reach and remote locations, such as oil rigs, wind turbines, and military outposts.
“With metal 3D printing, we have reduced the weight of the blades by 30%.” stated Claes Nicolajsen, CTO at Acodyne. “This weight reduction has cascading effects, 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.”
Acodyne wanted to improve and further develop these using Additive Manufacturing. Therefore, they sought help in a MADE demonstration project with the Danish Technological Institute’s Additive Manufacturing specialists.
“We expected that with metal 3D printing, we could significantly reduce the weight of our blades. At the same time, 3D printing gives us the flexibility to quickly adapt and develop new designs, which is crucial for a company like ours that is constantly evolving our products,” said Mads Schnack, CEO at Acodyne.
A drone capable of transporting 200kg requires powerful motors. Acodyne specialises in this with its electric ducted fans, otherwise referred to as electric jet engines. The Danish Technological Institute was tasked with optimizing the blades’ design using metal Additive Manufacturing. The blades were weight-optimised without altering the outer geometry.
“We redesigned the blades, made them hollow, and added internal ribs, which was necessary to maintain strength and stability. The blades were printed in titanium, which is a light and strong material. With these changes, we managed to reduce the overall weight without compromising the blade’s structural integrity,” Magdalena Susanne Müller, consultant at the Danish Technological Institute, shared. “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.”
Acodyne has achieved a weight reduction of 90 g per blade – or up to one kilo per engine – which, according to Mads Schnack, provides Acodyne with great value.
“When it comes to flying objects like drones and planes, weight is crucial. The lower weight of the blades will make our products faster in speed, but also quicker in reaction time. It is a significant competitive advantage,” added Schnack.
Even though the unit price is slightly more expensive compared to Acodyne’s old blades. Claes Nicolajsen said, “Considering the cascading effects, we expect to be close to break-even. We may have already achieved a gain.”
The new blades are lighter and more durable than the previous versions. They weigh approximately one-third of the original, which saves up to one kilogram per engine, leading to reduced energy consumption and faster acceleration. Additionally, creating new 3D designs and manufacturing the blades is simpler compared to traditional methods, such as making new molds. The new blades also exhibit superior uniformity in both weight and geometry, and they are easier to repair.
