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Product1 publisher3 min readPublished

Tobyhanna-assembled motors fly a printed Group 1 drone for eight hours and 41 minutes

The Army's brushless motor line at Tobyhanna Army Depot was just over two weeks old when its motors carried a printed Group 1 drone about 300 miles in the California desert. Whether industry can buy them is another matter.

The Product Desk · Product desk

Photograph accompanying Tobyhanna-assembled motors fly a printed Group 1 drone for eight hours and 41 minutes
Photo: interestingengineering.com

What happened

  • Two brushless direct current motors assembled at Tobyhanna Army Depot powered a Group 1 small UAS for eight hours, 41 minutes and 43 seconds at the Game of Drones 26-2 demonstration at Edwards Air Force Base on July 15-17.
  • The aircraft covered approximately 300 miles before landing safely, 50 minutes longer than the previous record, according to the Army release.
  • Designed in under 10 minutes using computer prompts in adaptability software, the airframe was fabricated on commercial 3D printers inside a mobile containerized factory within 24 hours of takeoff by a three-person team.
  • The Army is also assembling small UAS frames at Rock Island Arsenal-Joint Manufacturing and Technology Center in Illinois and batteries at Red River Army Depot in Texas.

Compiled by The Product DeskSomething wrong?How this is made

Why it matters

  • capability An integrator that needs domestically sourced propulsion now has a public flight time to cite for a depot-assembled motor when a contracting officer asks what the compliant part gives up.
  • constraint The figure belongs to a printed airframe matched to those motors on site within a day. A program planning a retrofit of an existing platform cannot budget for eight and a half hours.
  • decision Anyone writing a Group 1 endurance requirement has to weigh a domestic result they can hold vendors to against a production line that was 15 days old on the day it was demonstrated.
  • precedent If depot frames and batteries reach the same approval standard, the Army becomes a supplier to the companies bidding its own drone programs, and sourcing difficulty gets harder to plead in a proposal.

The person who has to act on this is whoever writes the propulsion line in a Group 1 bill of materials and then defends it to a contracting officer. The Army's stated reason for building the capability is to eliminate foreign dependencies for critical parts [9]. What the Edwards flight adds is a flight number a compliant motor can be sold with.

About 300 miles in 8 hours 41 minutes 43 seconds is an average of roughly 34.5 mph [3]. Subtract the 50-minute margin the Army release claims and the mark it beat sat near 7 hours 51 minutes [1], an improvement of close to 11 percent [2].

The airframe was printed on site and integrated with those two motors and a partner's battery inside a day, then flown [4]. A unit retrofitting depot motors into a fielded platform is buying two motors whose best published result came inside an aircraft built around them in 24 hours.

Fifteen days separated the ribbon cutting from the start of the demonstration window [4]. "This is a huge milestone for AMC and Tobyhanna, considering the fact that we just cut the ribbon on the new brushless motor line on June 30," said Jon Strzelec, the AMC advanced manufacturing lead for small UAS [6]. A line that new has a yield and a scrap rate that so far only the depot knows. The release does not give a unit price, a lead time, or a quantity available to industry [5].

The ambition on the record goes past supplying soldier innovation labs. "From providing components to soldiers at innovation labs, to providing industry clean supply chain solutions in support of drone dominance, it is our goal to continue to participate in events that demonstrate our capabilities and help refine our components for the warfighter based upon realistic testing," said Army Capt. Lee Washburn, the AMC military liaison for advanced manufacturing of small UAS [10]. The depot wants to sell into industry's supply chain, and the event itself was sponsored by the Defense Contract Management Agency blue list team [9].

This turns from a press item into a sourcing option once you know whether you can order the tested stack or only the motor inside it, and what quantity lands on what date. Anyone chasing the endurance figure also wants to know how much of the 8 hours 41 minutes belongs to the motors as against the industry battery and the printed airframe, since the release credits all three [4].

Until those are answered, the checkable part is narrow. Two motors from a line 15 days old flew one purpose-built aircraft for more than eight hours in desert heat [12].

What to watch

  • Whether DCMA adds the Tobyhanna motor to the blue list with a part number industry can specify in a bid.
  • Whether the depot publishes a price, a lead time, and an order route for non-government buyers.
  • Whether a later Game of Drones flight combines Rock Island frames, Red River batteries and Tobyhanna motors in one aircraft.
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