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Why sense & avoid is moving to ground-based systems

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Focus on advances in composite materials

Wing-folding
wonder
How the PteroDynamics X-P4 exploits some
UST 41 : DEC/JAN 2022
innovative VTOL-transitioning technology

Read all back issues online

UK £15, USA $30, EUROPE e22 www.ust-media.com
December/January 2022 | Contents

22 36

46 54

62
04 Intro 62 Dossier: NWFC-1500 fuel cell
As regulations catch up with the technology, so unmanned In a unexpected expansion from supplying multi-fuel engines,
systems are reaching a point where they will be an everyday sight Northwest UAV has produced this hydrogen fuel cell. We report
on why it has done so and how it developed the cell
06 Platform one: Mission-critical info
Driverless car hire service uses remote driver for delivery and 72 Show report: DroneX 2021
collection, tethered UAV controlled by machine learning, closed- Highlights of some of the new developments showcased at this
loop system tests car radar sensors, and much more recent expo at London’s ExCel centre

18 In conversation: Janek Biskupski 76 In operation:

GE Aviation’s principal engineer discusses the company’s new Hefring Engineering OceanScout
aero engine – its first in 50 years We find out how this buoyancy-driven UUV has been designed
and built to ‘democratise’ the scientific research of our oceans by
22 Dossier: PteroDynamics X-P4 small teams on a strict budget
We explain how this UAV’s unique VTOL-transitioning technology
was developed and what its advantages are 82 Focus: Composites
In line with the growing sizes of unmanned vehicles, composite
36 Focus: Sense & avoid systems materials developers are turning to ways of increasing strength
Why sense & avoid is moving to ground-based radar and and stability while reducing waste and costs
unmanned traffic management systems
92 Show report: DSEI 2021
46 Digest: 4Front Robotics Cricket Our round-up of some of the newest military-grade products on
If you’re looking for a UGV that can climb up pipes and along display at this world-leading defence and security exhibition
tunnels, this one certainly has the legs for it
98 PS: Extra-large naval UUVs
54 Insight: Autonomous transport We look at why the 50-ton Orca concept XLUUV is being
All the talk about these systems is being turned into practical developed for the US Navy, and how it will fit into its vision of a
services, as the companies here are showing more distributed fleet architecture

Unmanned Systems Technology | December/January 2022 3

This UAV’s unique VTOL-transitioning technology
gives it advantages over other VTOL systems.
Rory Jackson explains how it was developed

Transition
elements
T
he professional UAV the case of US-based PteroDynamics, The X-P4 is a 4 m wingspan all-electric
industry has spawned a which has developed a unique aircraft, with a nominal MTOW of 75 lb
multitude of approaches to VTOL-transitioning solution in which (34 kg) and a maximum endurance of
producing safe and robust transversely folding wings move a UAV’s 3 hours when cruising at 45-50 knots
VTOL-transitioning systems. electric drives from a forward-facing (52-58 mph). It offers a 6.8 kg nominal
Most have taken the route of a multi- arrangement for flight to one that points payload weight (within a 28 litre payload
copter hybrid, such as those from Alti upwards for hovering. volume), although up to 11.8 kg can
Transition (UST 8, June/July 2016) with The company says the system, called be carried if the end-user is happy to
vertically disposed electric motors on the Transwing, has various advantages sacrifice battery packs and hence range
fixed booms. Other manufacturers have over other VTOL systems for fixed-wing and endurance.
developed tiltrotor aircraft, such as those UAVs, from better aerodynamics and
from Quantum Systems (UST 14, June/ agility to greatly reduced mechanical Company history
July 2017) and Wingcopter (UST 24, and software complexity, as well as a far The Transwing technology was invented
February/March 2019), or tail-sitters from smaller ground footprint relative to its in- by Dr Val Petrov, founder and CTO of
the likes of Martin UAV (UST 15, August/ flight dimensions. It is used on its flagship PteroDynamics, who moved to the US
September 2017) and UAV Works (UST aircraft, the X-P4 UAV, which is on track from the former Soviet Union in 1990
32, June/July 2020). for delivery to the US Navy next year. while still a PhD student, specialising in
And the innovations continue. Take There is also a smaller version, the X-P2. control theory and non-linear dynamics.

22 December/January 2022 | Unmanned Systems Technology

PteroDynamics X-P4 | Dossier

PteroDynamics’ transitioning
architecture is computationally simple
and allows a high aspect ratio wing
(Images courtesy of PteroDynamics)

The Transwing uses its four electric

motors in cruise, forward flight and
relatively short wings, despite being less transitions between the two
aerodynamically efficient for flight.”
Dr Petrov ruminated on this until 2016,
when he began conceiving a way to fold any difficulties,” Dr Petrov adds. “The
his aircrafts’ wings (partially influenced first 4 m wingspan prototype was critical
by the Sto-Wing technology patented by to proving that: if we were prone to any
Grumman for the F4F-4 Wildcat) using wind stall on larger wings, it would have
a rearwards-folding element to direct its shown up in one of its test flights. Instead,
propellers upwards. transition and flight were performed
After building parts for a prototype from perfectly, with high controllability at all
balsa wood, he iterated many blueprints speeds and power outputs.”
of wing-folding until arriving at one he The company began pitching its design
Although he spent much of his thought would work. He constructed to potential customers in 2018, shortly
subsequent professional life in investment the mechanisms, installed them in the after Matthew Graczyk joined as CEO.
management, he took up aeronautics as 3 lb aircraft (along with rudimentary RC The following year, the US Navy asked
a hobby, mainly through remote control electronics and controls), and found to his to test a Transwing aircraft, awarding
(RC) planes and helicopters. shock that it transitioned from vertical take- PteroDynamics a contract for the Blue
“I spent more than 20 years flying off into forward flight without any issues. Water ship-to-ship logistics project
RC, and I’d always wanted to combine Recognising what his technology was soon after; the X-P4 was subsequently
my planes and helicopters into a single capable of, he hurriedly patented it and designed around this requirement.
aircraft,” he recounts. sought partners to start a company. A Vice-president of engineering Tim
“I especially wanted to combine a new prototype with a slightly improved Whitehand joined PteroDynamics in early
high-aspect ratio wing, which is ideal transitioning mechanism was built 2020. He is a seasoned engineer and
for highly efficient and fast forward and entered testing in mid-2017, which aviator experienced in the design, build
flight, with a VTOL capability. But long, accomplished about 200 flights before and testing of numerous unmanned
thin wings make aircraft hard to control crashing because of an aileron servo and optionally piloted experimental
when they’re anywhere near the ground, failure. aircraft, and worked to establish a team
especially with crosswinds that can “We’ve built prototypes of many different of engineers focused on maturing the
‘catch’ and pull them around. That’s why MTOWs and wingspans, and found that company’s technologies, processes and
most VTOL-transition engineers opt for the Transwing technology scales without capabilities.

Unmanned Systems Technology | December/January 2022 23

Dossier | PteroDynamics X-P4

To transition between cruise and VTOL, a linear

actuator moves a clip with two pushrods up
and down the centreline of the UAV

company’s roadmap includes r&d into

optimising cables and plugs for sealing
and EMI shielding.
“At no turn have we opted for any
exotic parts in this vehicle,” says
Whitehand. “We use traditional, well-
proven materials, design methods and
COTS components. System integration,
controls development and automation
are where we see the most opportunity
for innovation.
“Keeping the powertrain in the wings
may seem unusual but it yields great
inertial relief, air cooling and a simplified
structure, because the back tips of the
nacelles act as landing struts.”
Whitehand notes that the four electric
motors together can deliver up to 10
times the necessary power for cruise.
So, while all four are used in VTOL, with
a peak climb rate of 1000 ft/minute and
more, the X-P4 will typically shut off two
motors during cruise, with their propellers
passively folding back (pushed by
airflow) and sitting tightly against the
aerodynamic profile of the nacelles to
lower power consumption and drag.
“The high available power means we
could fly comfortably at altitudes above
System architecture approach to its aircraft designs, 10,000 ft, but we’ve not tested that out,”
Numerous key technologies have been anticipating that different use-cases will he adds. “As interesting as it would be
combined in the X-P4, with three patents require different airframes, aerofoils and for us to find out, it’s not exactly a priority
already granted and five more pending tailplanes, a few key features currently for customers.”
that formalise and globally protect stand out. Several hundred test cycles of sub-
PteroDynamics’ subsystem designs. These include a high aspect ratio wing components have been performed, with
As Graczyk explains, “A lot of big UAV and a vee tail with a largely composite final qualification testing for the US Navy
companies have dozens of patents, hull. In addition to the 4 m wingspan, the planned for 2022.
but they are on individual components, fuselage measures about 2 m long.
like perhaps the method and design 2.2 kWh of energy is stored in COTS The Transwing
of lowering packages from a hovering lithium-ion batteries that sit in the four In a Transwing aircraft, each wing
aircraft. Our principal patent family covers wing-mounted propulsor nacelles, along attaches to the fuselage via a rotary
the entirety of the Transwing aircraft with the electric motors and ESCs, and hinge – each hinge is set at an angle –
design, including the articulating wings, a CAN bus running data between the with an actuation system for deploying
the design of the propulsors on the nacelles and the fuselage-mounted and stowing them.
wing, and how the wings rotate with a autopilot. Lightweight COTS wiring While each hinge sits on a winglet-like
symmetrical dihedral.” harnesses with locking connectors run protrusion on either side of the forward
While the company takes a modular between these systems, although the fuselage, the actuator (a linear worm-

24 December/January 2022 | Unmanned Systems Technology

The Quattro autopilot and ground
interface solutions from Applied
Navigation are used in X-P4s for 4 m wide to about 1.2 m). X-P4s can thus
defence users be stowed in cases or compartments
without having to be disassembled, just
Each pushrod connects to the inner-rear
section of its closest wing to achieve the as Grumman’s Sto-Wing maximised the
transverse folding and unfolding movements The disposition of the hinge (and thus number of F4F-4s that could fit on an
the angle of rotation between the two aircraft carrier.
extremes of wing positioning) can vary Furthermore, the folding of the wing
drive servo) sits further back, near the tail, between Transwing aircraft designs. makes for a much more stable VTOL. As
and when powered moves a clip with two While the X-P4 has been designed mentioned, a larger aerodynamic surface
external pushrods that act on the inner- with high robustness and controllability means a greater impact from crosswinds
rear sections of either wing. The wings thus of transitioning for the US Navy (with and gusts whenever fixed-wing aircraft try
pivot about the hinges, to fold against the ongoing tests validating these), future to land or take off.
fuselage or unfold into their flight angles. r&d will examine how the aerodynamics That could pose severe issues for tail-
“The hinges need to withstand the loads change during transition, to see if there is sitters, or for tilt-wing UAVs such as NASA’s
imparted during transition, and meet key an optimal angle from that perspective. Greased Lightning, as large landing pads
stiffness requirements to be able to manage “While we’ve had hundreds of real- could be needed to avoid endangering
during both hover and flight,” Whitehand world tests, developing robust aero technicians during recovery. Dr Petrov
says. “The wings are passively locked into and performance estimation is a key notes here that the X-P2 by contrast has
place after take-off by way of a secondary ingredient to maturing the technology,” been flight-tested amid 55 mph gusts, and
wing interlock, so that the actuator isn’t Whitehand says. “And while most of performed VTOL autonomously to well
needed for holding the wings in place. our analysis currently relies on proven within safe levels of stability.
“The worm drive was chosen to be first-order methods and empirical data Whitehand says, “The Transwing
as lightweight and reliable as possible, validated through testing, selective design has a very broad transition
with an efficient and accurate encoder to CFD and wind tunnel tests will play an envelope. A lot of tiltrotors and tail-sitters,
allow us to tightly control its position. important role in taking advantage of the like helicopters, have to climb to a certain
“As Val’s tests have proven, we can differentiating aspects of the technology.” altitude before switching to forward flight,
safely fly the X-P4 in all modes of As mentioned, the Transwing creating numerous constraints on speed,
transition, because when the wings fold system has some key advantages power, angle of attack and so on.
in it just behaves like a quadcopter. over other, better established VTOL- “By contrast, we’re very tolerant of
So although we’re relying on a single transition systems. The most visible is multiple outbound and inbound transition
electromechanical device, it doesn’t compactness: as the wings fold tightly profiles, speeds, weights and external
constitute a point of outright failure in the along the fuselage, the craft’s footprint is disturbances. We can start transitioning into
traditional sense.” greatly narrowed when landing (from cruise almost immediately after launching,

26 December/January 2022 | Unmanned Systems Technology

PteroDynamics X-P4 | Dossier

and we want to expand that envelope over Whitehand explains. “We’ve found that (which handles military transport and
the next 6 months so that customers have flying faster is a huge differentiator replenishment) needed a fast, reliable,
a broad flight envelope to work with.” among customers looking into last- easy-to-use aircraft with high tolerance
As mentioned, since wing length mile aerial logistics. Among industrial to hazardous weather conditions, to ferry
contributes little to ground footprint or or defence users who need, say, a repair tools and parts to ships.
near-ground instability, a high aspect critical repair tool or replacement part “Those parts and tools are typically
ratio wing can be designed to maximise for broken-down vehicles or machinery, delivered by H-60 and V-22 aircraft,
flight efficiency and hence endurance. moving fast is much more important than which are incredibly expensive and high
Dr Petrov adds, “Since we use the same being able to fly far. maintenance, even though 90% of the
propulsors on the wings for both VTOL “For those users, a 3 hour flight time they’re carrying payloads of 50 lb or
and forward flight, we don’t need to carry endurance is surplus to requirements; less for these missions,” Graczyk says.
the dead weight and severe parasitic drag instead, we could carry a 15 lb payload “After showing what our aircraft could
that hybrid multi-rotor planes have to in at 75 knots for 1.5 hours. Right now, we do for them, we signed the contract in
their VTOL systems, or the added points of estimate our dash speed to be 150 knots June 2021 to deliver three X-P4s in June
failure that tiltrotor servos pose. with variable-pitch propellers, and once 2022 as demonstration units, which
“That means we gain not only we’ve incorporated some further things in might be extended to more units and
endurance and lift-to-drag ratio, but also our r&d pipeline, we’ll be able to get all the larger variants in a follow-on contract.”
airspeed, since we can devote more speed these customers will ever need.” Vice-president of business
power to forward propulsion. Based on development Chris Corgnati notes
my calculations, I am confident that we will Modular mission systems that the reliability, speed and carrying
soon break the world speed record for a As mentioned, the initial customer for the capacity of the X-P4 also mean that
VTOL UAV [currently 150 mph/240 kph, set X-P4 is the US Navy, for the Blue Water PteroDynamics sees commercial ship-to-
by Wingcopter in 2018].” Maritime Logistics programme. More ship and shore-to-ship logistics as highly
There is tangible value in this, as specifically, the Military SeaLift Command applicable for it and successive

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Dossier | PteroDynamics X-P4

PteroDynamics has tested (and keeps in one set of rules to the other as the wings
store) a wide range of BLDC motor and unfolded, and that was all – and it worked.”
propeller pairings, to mature and optimise
Specifically, the strength of the
the full range of its UAVs’ flight envelopes
autopilot’s PID control feedback loop
(much like those typically used in
distributed-lift UAVs) is linearly reduced
by the position of the worm drive, rather
than a hard, binary switch, as the wings
unfold into their fixed-wing angle.
“All the flight controller needs to know
is when it’s supposed to transition,” Dr
Petrov adds. “It doesn’t physically need
to look at the altitude or airspeed, and
we know from hundreds of test flights
that the transition will be very benign and
controllable, without any significant loss
or gain of altitude. The most common
effect is some loss of speed as the aircraft
decelerates during inbound transition, or
speed gain during outbound transition.”
Therefore, the main purpose of the
flight controller is not to handle any
complex transition algorithm, but to
ensure an appropriate robustness of
flight autonomy and hence consistent
endurance for the end-user.
“We have developed a Matlab model
UAVs. Similar repair logistics missions efficiency. Access requires no tools, and of our aircraft to better understand the
could be provided for armies, air forces, all airframe components are retained interactions between the aerodynamic
oil & gas platforms and remote industrial without having to be removed.” and propulsion forces, hinge flexing
facilities, as well as delivering emergency and feedback control actions during the
medical products or aid packets. Flight control and avionics transition regime,” Dr Petrov comments.
“Mapping or intelligence missions The VTOL-transition systems we have “We have analysed multiple
might seem straightforward and less previously featured in this magazine implementations of this model spanning
urgent than all these delivery and relief rely largely on complex algorithms a range of sizes and weights up to
operations, but we can certainly do them,” for transitioning that took enormous 5000 kg MTOW. We concluded that the
Corgnati adds “We can adjust the wings development time and rigour. transition flight envelope is robust and
and tailplane to trade off between speed, PteroDynamics has a strikingly different independent of the size and weight of
endurance, payload stability and so on.” story. As Dr Petrov discovered in the the aircraft, even with the simple linear
To carry all the different items across maiden test flight of his balsa prototype in controller gain scheduling. We have also
these missions, a payload bay is 2016, the Transwing transition approach developed RealFlight models of the X-P2
installed in the front as standard. A single requires very little of the UAV’s autopilot in and X-P4 to test the flight regimes using
hinge under the nose allows this section terms of sensory inputs, processing load the Ardupilot SITL environment and the
to swing open, to reveal a square- and control outputs. native RealFlight stabilisation systems.”
shaped 1 cu ft volume for installing “I made that first flight and transition To date, PteroDynamics has flown
packages. If needed, this section can with a $10 KK2.1 flight controller,” he Transwing aircraft using three different
be turned into a mounting point for a recounts. “I programmed it with a really flight controllers: KK2.1, Ardupilot and
retractable camera gimbal. simple gain scheduling algorithm, to Applied Navigation’s Quattro FMS.
“We want even the most inexperienced handle the gradual change of controller “While the simple KK2.1 controller
personnel to be able to use the aircraft,” laws from a quadcopter configuration was sufficient to stabilise our aircraft, we
says Corgnati. “The payload is housed to a comparatively simple fixed-wing have progressed to other, more mature
internally to maximise aerodynamic configuration. It’s a linear change from flight control systems that enable

28 December/January 2022 | Unmanned Systems Technology

One of PteroDynamics’ propulsion testing rigs and leverage the broader Ardupilot
ecosystem where we’ve needed to,
thereby supporting a wide range of
peripheral devices,” Whitehand notes. “It
also means our commercial customers
can easily make use of other Ardupilot
add-ons for whatever niche missions or
manoeuvres they want to carry out.”
While some among people in the
defence services are increasingly
interested in open source technology for
its community-driven agility, many are
still dubious of having such transparency
in their subsystems. For those users,
including the US Navy, PteroDynamics
has integrated Applied Navigation’s
Quattro autopilot to operate the X-P4.
“Applied Navigation implemented
our flight control modules and gain
scheduling into the Quattro,” Whitehand
says. “What that gets us compared with
the very flexible, open source Ardupilot
is a far more powerful hardware
architecture that can support the kind of
peripherals we need in order to deliver
the X-P4 to a government or military
customer, or easily scale up the aircraft
for similar customers who might want to
carry more weight.
“Applied Navigation also provides the
Vigilant Spirit operator interface, which
many US defence-sector customers
are experienced with. And I understand
Applied Navigation was also recently
approved for BVLOS operations in
Spain, which we feel has further
validated our choice to go with the
Quattro in the defence market.”
The radios and antennas are also
installed throughout the fuselage, rather
Velocity HS ESCs from Currawong are
installed on the X-P4 to ensure sufficiently than in the routinely mobile wings.
reliable operations for its US Navy customer For standard-issue comms, dipole
omnidirectional antennas enable data
uplinks and downlinks over the 900 MHz
higher levels of reliability, customisation as it is an open source solution with a and 2.4 GHz bands.
and automation,” Dr Petrov says. “We large community of developers providing “We’ve played a bit with our ground
continue to work closely on this with our ways to adapt and tune different planes and antenna positioning, and
control partners Applied Navigation, KH algorithms to work with the hardware. we’re confident now that we have solid
Unmanned and Aerial Robotics Australia.” “The additional code we’ve written comms over a 10 mile distance, which is
For commercial users, PteroDynamics on top of Ardupilot’s master branch is far more range than we need,” Whitehand
typically uses Ardupilot systems such as actually very minimal. That’s enabled says. “That said, we have the backbone
the X2.1 777 board from Mayan Robotics, us to fly the aircraft in different ways to accept any IP mesh radios, satcom

30 December/January 2022 | Unmanned Systems Technology

PteroDynamics X-P4 | Dossier

and more powerful links, along with the efficient air-cooling inherent in the electric variable-pitch propellers in the
pretty much any transponder systems propulsors’ design, and their modularity, future will not only boost prop efficiency,
end-users might want. It’s just a matter means others can be used, providing it will allow us to use less powerful
of being certain what they want, before they supply the power output necessary motors during VTOL. It will also save
going through the lengthy FCC licencing for all stages of flight. on manufacturing and operating costs,
process to fly them.” “The X-P4 uses about 7-8 kW to hover, which is why variable-pitch is a significant
and when we’re cruising at 65 knots or item on our roadmap.
Propulsion so the motors draw about 1.8 kW with “Another area we’re looking into
As indicated, the X-P4 features four fixed-pitch propellers,” Whitehand says. is small asynchronous motors. A lot
propulsor nacelles, each of which “If we’re dashing at 75 knots though, of efficiency losses in permanent
contains a BLDC electric motor, an power consumption is about 2.5 kW, and magnet BLDC motors come from the
ESC and a lithium-ion battery pack with naturally, when we’re transitioning, there’s demagnetisation of their iron cores, so
about 550 Wh of energy. Each nacelle a power curve that varies between the if we can have an asynchronous motor
has a battery panel (held in place by values for hover and cruise. For example, where we control the strength of the
two screws) for removing and replacing if we’re inbound, we can do a low-power magnetic field, we could significantly
the battery packs, although the team is extended flare approach, or if an end- improve efficiency in forward flight.
looking at ways to recharge the plane user’s coming in hot and wants to do a “The only problem there is that,
without having to change the batteries. quick stop, then obviously that’s going to currently, no-one really makes three-
Various motor-propeller combinations be sharper and more power-intensive.” phase AC induction motors at the right
have been trialled (and are kept on the Petrov adds, “There is a slight trade- SWaP for our requirements, but it’s
engineering team’s racks) to identify ideal off here, in that we want to use powerful something we’re keeping an eye out for.
combinations of speed and torque for motors for take-off, hover and landing, “We’re also working with GM Propellers
different mission requirements. Although but when we’re cruising we don’t really and Mejzlik on improving the performance
T-Motor motors are used at the moment, need high power at all. Switching to of our current fixed-pitch propellers.

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Dossier | PteroDynamics X-P4

for customers requesting longer flight

Specifications times, greater carrying capacities or just
reduced downtime. Gasoline, heavy fuel
and hydrogen systems alike are open
PteroDynamics X-P4 VTOL-transitioning UAV for consideration, including IC engines
VTOL-transitioning UAV and fuel cells. Microturbines suited
Wingspan: 2 m to the X-P4’s weight class, efficiency
Wingspan: 4 m Length: 1.03 m requirements and MTBF remain rare.
Length: 2 m MTOW: 10 kg Meanwhile, the electric motors are
MTOW: 34 kg Payload volume: 3 litres controlled by Currawong Engineering
Payload volume: 28 litres Standard battery energy: 0.7 kWh ESCs, chosen for their long life and
Standard battery energy: 2.2 kWh Standard payload capacity: 2.2 kg reliability. Whitehand and Dr Petrov
Standard payload capacity: 6.8 kg Maximum payload capacity: 3.1 kg emphasise that ESCs often come up
Maximum payload capacity: 11.8 kg Maximum endurance: 2 hours as the highest-risk components during
Maximum endurance: 3 hours Maximum speed: 150 kph UAV failure analyses, being routinely
Maximum speed: 280 kph Cruising speed: 95 kph subjected to surges that can break them
Cruising speed: 105 kph and hence the powertrain.
MTBF: At least 100 hours Some key suppliers
Aero
Some key suppliers Autopilot & controls: The shape of the X-P4, particularly
Applied Navigation its high aspect ratio wing, outwardly
Autopilot & controls: Autopilot & controls: resembles a glider more than an
Applied Navigation Mayan Robotics archetypal high-speed aircraft. Initial
Autopilot & controls: Airframe manufacturing: designs of its profile were calculated and
KH Unmanned Vibe Composites conceived based on first engineering
Autopilot & controls: Folding propellers: GM Propellers principles and available bodies of
Aerial Robotics Australia Electric motors: T-Motor empirical data.
Autopilot & controls: ESCs: Mezon “We are putting more resources
Mayan Robotics into the analytical modelling of the
Aerodynamic analysis Transwing to identify opportunities for
consultation: optimisation and establish a strong
Flighthouse Engineering Because the Transwing uses the same technical basis on which to scale the
Mechanical design consultation: propulsion system for VTOL and cruise technology; however, we place a high
Flighthouse Engineering flight, any fixed-pitch system will be a priority on flight testing to support our
Airframe r&d: compromise, but a variable-pitch propeller claims,” says Whitehand.
Tumbleweed Composites set-up would solve that. We would be
Fuselage manufacturing: very excited to find a group interested in Structural design
Composites Universal Group developing that with us.” and materials
Wings and vee-tails: Whitehand adds, “We are also The structural design of the X-P4 is
Ultimate Composites exploring things such as different largely driven by experience-based
Folding propellers: GM Propellers propeller solidities and acoustics. Our decision-making combined with
Additional propeller consultation: customers aren’t necessarily looking selective use of FEA and mechanical
Mejzlik for those right now, and using unusual testing. Airframe materials and
Electric motors: Hacker propeller designs can add risk, but we mechanical architectures were
ESCs: Currawong Engineering want to know how to add efficiency selected with a heavy emphasis on
PteroDynamics X-P2 so that we’re ready when the market manufacturability and cost.
demands it.” Its airframe is made predominantly from
Barring some unexpected leap a minimum gauge (thinness) composite
forward in the commercialisation of sandwich structure using carbon, Kevlar
new, high-density battery chemistries, and fibreglass. Core materials include
PteroDynamics expects to use some low-density closed-cell polyethersulfone
form of hybrid power unit in the future foam and balsa wood. High-load

32 December/January 2022 | Unmanned Systems Technology

Dossier | PteroDynamics X-P4

The X-P4’s wings come in Queensland, Australia, which has an

from Ultimate Composites, innovative clamshell moulding process
the nacelles from
using pre-preg carbon and a proprietary
Composite Universal Group
foam-moulding process to produce wing
structures with a high specific strength.
“We involved our manufacturing
partners early in the design process of the
X-P4, giving them the opportunity to steer
the design according to their wisdom and
experience,” Whitehand says.
The materials and methods used
to manufacture the X-P4 are currently
geared towards low-volume, labour-
intensive methods to allow rapid in-
process changes. “As the X-P4 matures
though, the manufacturing methods
will evolve to high-volume, low cycle
time processes,” Whitehand says. “The
foundation for those has already been
baked into the X-P4’s design.”

Future plans
PteroDynamics is pressing on with the final
r&d phases for its US Navy customer, with
specialised test stands being completed
for cycling the X-P4’s subsystems
individually to the required standards.
As indicated, future models for navies
and elsewhere might use a range of
technologies, and the company is
expanding its capabilities to that end,
having moved its headquarters for r&d
and production to Colorado Springs at
the end of July 2021.
“We’re in ongoing discussions with
two very large US defence primes about
teaming opportunities,” Graczyk adds.
“We’re now doing feasibility studies
The company is continuing its r&d into different subsystems and into a 12,000-plus lb MTOW Transwing
larger versions of its UAVs, for defence as well as other uses craft, a 5000 kg version, and another
with a 250 kg payload to support
those opportunities. We are also in
elements such as the wing hinge are exceptional track record on numerous further talks for a range of cargo and
machined from 6061-series aluminium, manned and unmanned aviation intelligence operations across the US
and 3D-printed SLS materials are used projects and its adaptable and pragmatic Department of Defense, and a project
throughout the aircraft. approach to aircraft manufacturing. solicitation from a large international
The company works with a few X-P4 fuselages and nacelles are defence prime.
partners for airframe manufacturing. manufactured using traditional vacuum “More recently, we’ve been contacted
Whitehand explains that for the X-P4, the bag open-mould methods using out- by one of the largest commercial
fuselage and nacelles are manufactured of-autoclave (or ‘out-of-oven’) resin shipping companies in the world, which
by Composites Universal Group in systems. The wings and tails are is looking for something largely identical
Oregon, US, which was chosen for its manufactured by Ultimate Composites to the X-P4 for maritime logistics.”

34 December/January 2022 | Unmanned Systems Technology