US Army Tests Drone Powered by a 3D-Printed Engine

The US Army has tested a drone powered by a hybrid propulsion system manufactured using 3D printing.

The engine runs on heavy fuel and was developed by specialists at the US Army Research Laboratory.

Heavy fuel allows the drone to stay airborne longer than conventional gasoline or battery power.

The US military said the development marks an important step forward in energy and propulsion systems for tactical drones.

Such engines are expected to provide longer flight endurance, higher speeds, the ability to operate at high altitudes, carry heavier payloads, and perform missions in extreme conditions. They will also help reduce logistical demands.

The research findings have already been shared with industry partners for further technological development and integration into future military platforms.

During engine development, researchers used computational fluid dynamics simulations and designed the engine virtually from scratch.

This enabled researchers to overcome the challenge of efficiently combusting heavy fuel in a rotary engine.

In particular, engineers improved the fuel atomization and vaporization processes while reducing leakage of compressed air and fuel vapors.

Metal 3D-printing technology enabled engineers to rapidly modify the engine design based on experimental results.

This made it possible to develop an air-cooled engine that reduces the overall size of the propulsion system and eliminates the need for a separate liquid cooling system.

Innovative Engine

Combined with a 400 V electric motor-generator, the engine forms a heavy-fuel-powered series hybrid propulsion system.

The system is designed for vertical takeoff and landing (VTOL) unmanned aircraft, including operations in contested environments.

To test the new propulsion system in flight, researchers integrated it into the VICTOR unmanned aircraft, developed byGriffon Aerospace.

VICTOR is a US-made medium-class unmanned aerial vehicle (UAV) designed for reconnaissance and strike missions.

According to the US Army’s classification, it belongs to Group 3 unmanned aircraft. This category includes systems weighing up to 600 kg and capable of operating at altitudes of up to 5.5 km.