{"id":43348,"date":"2023-03-21T09:25:54","date_gmt":"2023-03-21T13:25:54","guid":{"rendered":"https:\/\/www.shapeways.com\/blog\/?p=43348"},"modified":"2023-03-28T16:43:22","modified_gmt":"2023-03-28T20:43:22","slug":"pyka-case-study-3d-printed-parts-additive-manufacturing-aviation","status":"publish","type":"post","link":"https:\/\/www.shapeways.com\/blog\/pyka-case-study-3d-printed-parts-additive-manufacturing-aviation","title":{"rendered":"Pyka\u2019s Autonomous Aircraft Soar With 3D Printing Innovation"},"content":{"rendered":"\n<p class=\"wp-block-paragraph\"><em>Sleek, fast, and fully-automated<\/em>. <a href=\"https:\/\/www.flypyka.com\/\">Pyka\u2019s<\/a> signature electric aircraft are transforming the future of cargo transportation with faster deliveries, improved safety, and efficiency\u2013from ease in taking off to flying in harsh weather conditions.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The expanding product line of the California-based aviation company continues to showcase their impressive vision and versatility, fueled by <a href=\"https:\/\/www.shapeways.com\/upload-3d-print-files-models\">3D printing<\/a>. After mastering design and production of autonomous aircraft for agricultural applications like crop-spraying, Pyka transitioned into developing new solutions for middle-mile cargo transport.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>Market Demand Required Modifications to Original Pyka Aircraft Designs<\/strong><\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Pyka had great success in producing their first electric airplane, the Pelican Spray, and working in other aerial applications. They quickly piqued the interest of cargo-transport companies.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">\u201cMarket leaders thought our technology would be perfectly suited for what they needed in moving cargo,\u201d said Jason Petersen, Senior Mechanical Design Engineer at Pyka. \u201cSupply chain influenced that a bit, but overall, the aviation industry was primed to advance and our electronic aviation technology was the most sophisticated.\u201d<\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"1095\" height=\"840\" src=\"https:\/\/www.shapeways.com\/blog\/wp-content\/uploads\/2023\/03\/Component-1-1095x840.png\" alt=\"\" class=\"wp-image-43354\" srcset=\"https:\/\/www.shapeways.com\/blog\/wp-content\/uploads\/2023\/03\/Component-1-1095x840.png 1095w, https:\/\/www.shapeways.com\/blog\/wp-content\/uploads\/2023\/03\/Component-1-821x630.png 821w, https:\/\/www.shapeways.com\/blog\/wp-content\/uploads\/2023\/03\/Component-1-420x322.png 420w, https:\/\/www.shapeways.com\/blog\/wp-content\/uploads\/2023\/03\/Component-1-768x589.png 768w, https:\/\/www.shapeways.com\/blog\/wp-content\/uploads\/2023\/03\/Component-1-1536x1178.png 1536w, https:\/\/www.shapeways.com\/blog\/wp-content\/uploads\/2023\/03\/Component-1-2048x1571.png 2048w\" sizes=\"auto, (max-width: 1095px) 100vw, 1095px\" \/><\/figure>\n\n\n\n<p class=\"wp-block-paragraph\">Meeting the needs of new clients meant making changes to existing technology. Pyka spent a year modifying and creating new aircraft that could fly longer distances, hold more cargo, and would also be easy to maintain.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>3D Printing Accelerated Product Development &amp; Manufacturing<\/strong><\/p>\n\n\n\n<p class=\"wp-block-paragraph\">3D printing played a large role in streamlining those modifications, and has continued to accelerate Pyka\u2019s production development and manufacturing processes. \u201cPeople are often surprised at how often we use 3D printing in our aircraft,\u201d said Petersen.&nbsp;<\/p>\n\n\n\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"967\" height=\"775\" src=\"https:\/\/www.shapeways.com\/blog\/wp-content\/uploads\/2023\/03\/E-Stop-and-External-Interface-Panel.png\" alt=\"\" class=\"wp-image-43355\" srcset=\"https:\/\/www.shapeways.com\/blog\/wp-content\/uploads\/2023\/03\/E-Stop-and-External-Interface-Panel.png 967w, https:\/\/www.shapeways.com\/blog\/wp-content\/uploads\/2023\/03\/E-Stop-and-External-Interface-Panel-786x630.png 786w, https:\/\/www.shapeways.com\/blog\/wp-content\/uploads\/2023\/03\/E-Stop-and-External-Interface-Panel-420x337.png 420w, https:\/\/www.shapeways.com\/blog\/wp-content\/uploads\/2023\/03\/E-Stop-and-External-Interface-Panel-768x616.png 768w\" sizes=\"auto, (max-width: 967px) 100vw, 967px\" \/><\/figure>\n\n\n\n<p class=\"wp-block-paragraph\">While there are dozens of 3D printed parts on each aircraft, some examples include waterproofed fairings, cases for wires and smaller electronics, latch mounts, and user-interface panels. Pyka reports ease in designing around any problems, without ever having to worry about \u2018manufacturability\u2019 of parts in 3D printing.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">\u201cDesign freedom plays a large role in allowing us to prototype and make changes, strategically placing certain materials where we know added strength is necessary in the aircraft\u2019s geometry,\u201d said Petersen. \u201cWith 3D printing, we can create much lighter parts for complex structures, in comparison to injection molding or machining.\u201d<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Affordability in prototyping and production is a major advantage as the Pyka team is constantly testing parts and looking for ways to enhance their products, usually revising at least one 3D printed prototype per week. Their design team uploads 3D models to Shapeways quickly, receives instant quotes and printability analysis, and then also has the advantage of referring back to those same digital files for on-demand additive manufacturing.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>Advanced 3D Printing Thermoplastics Meet Pyka\u2019s Growing Needs<\/strong><\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The autonomous aircraft designers leverage technology like <a href=\"https:\/\/www.shapeways.com\/3d-print-material-technology\/sls\">Selective Laser Sintering<\/a> and <a href=\"https:\/\/www.shapeways.com\/3d-print-material-technology\/hp-mjf\">Multi Jet Fusion<\/a> because of the ease in redesigning parts, and maintaining them later. Materials like <a href=\"https:\/\/www.shapeways.com\/materials\/versatile-plastic\">Nylon 12 [Versatile Plastic]<\/a> make it possible to create durable yet flexible parts, while <a href=\"https:\/\/www.shapeways.com\/materials\/multi-jet-fusion-pa12\">MJF Plastic PA12<\/a> provides necessary properties like moisture- and chemical-resistance.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">\u201cWe\u2019ve experimented with metal 3D printing and other materials like <a href=\"https:\/\/www.shapeways.com\/materials\/polypropylene-sls\">Polypropylene<\/a>, but I find we always end up going back to the other materials because of their excellent strength properties. We\u2019re used to working with them, the outcome is predictable, and the price point is just hard to beat!\u201d said Petersen.<\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"1120\" height=\"810\" src=\"https:\/\/www.shapeways.com\/blog\/wp-content\/uploads\/2023\/03\/Component-2-1120x810.png\" alt=\"\" class=\"wp-image-43356\" srcset=\"https:\/\/www.shapeways.com\/blog\/wp-content\/uploads\/2023\/03\/Component-2-1120x810.png 1120w, https:\/\/www.shapeways.com\/blog\/wp-content\/uploads\/2023\/03\/Component-2-840x607.png 840w, https:\/\/www.shapeways.com\/blog\/wp-content\/uploads\/2023\/03\/Component-2-420x304.png 420w, https:\/\/www.shapeways.com\/blog\/wp-content\/uploads\/2023\/03\/Component-2-768x555.png 768w, https:\/\/www.shapeways.com\/blog\/wp-content\/uploads\/2023\/03\/Component-2-1536x1110.png 1536w, https:\/\/www.shapeways.com\/blog\/wp-content\/uploads\/2023\/03\/Component-2-2048x1480.png 2048w\" sizes=\"auto, (max-width: 1120px) 100vw, 1120px\" \/><\/figure>\n\n\n\n<p class=\"wp-block-paragraph\">Access to advanced, durable materials is critical because Pyka uses so many of the 3D printed parts to hold important aircraft components in place\u2013when installing a part requiring complete accuracy on top of a wing, for example\u2013or on a curved area of the aircraft.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Currently, the average Pyka aircraft includes 60-80 3D printed parts. The company\u2019s rapid expansion in agriculture and cargo transport is fueled by their ability to simplify design and production with additive manufacturing, resulting in 11 aircraft built and 45 more planned for deployment in the future.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong><a href=\"https:\/\/info.shapeways.com\/3d-printed-parts-for-cargo-planes-additive-manufacturing-in-aviation\" target=\"_blank\" rel=\"noreferrer noopener\">Read the full case study to learn more about Pyka\u2019s use of additive manufacturing in building their autonomous aircraft.<\/a><\/strong><\/p>\n","protected":false},"excerpt":{"rendered":"<p>Sleek, fast, and fully-automated. Pyka\u2019s signature electric aircraft are transforming the future of cargo transportation with faster deliveries, improved safety,&#8230;<\/p>\n","protected":false},"author":175,"featured_media":43352,"comment_status":"open","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[510,489,481,478],"tags":[3104,2740,3103],"class_list":["post-43348","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-3d-printing-industry","category-products-and-design","category-shapeways","category-community","tag-3d-printed-aircraft-parts","tag-3d-printed-parts","tag-additive-manufacturing-in-aviation"],"thumbnail":"https:\/\/www.shapeways.com\/blog\/wp-content\/uploads\/2023\/03\/Pyka-Pelican-Cargo-7-scaled.jpg","yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v23.9 (Yoast SEO v23.9) - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>3D Printed Parts for Cargo Planes - Additive Manufacturing in Aviation - Shapeways<\/title>\n<meta name=\"description\" content=\"To meet their transportation requirements, Pyka, a leader in automated aviation, would need to develop and manufacture custom parts for new aircrafts. 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