In a mini drone cast by AFS Corporate Member Aristo Cast Inc. (Almont, Michigan), 3D printed wax patterns and generative design were used to achieve a complex support structure. Freedom of feature and rigging element placement are offered by the additive manufacturing process because it doesn’t have tooling-related constraints. Lightweighting is achieved through thinner walls, highly cored geometry and generative design with topology optimization. Complex designs can be turned into reality with feature and part consolidations otherwise impossible with a conventional tooling approach. In this case, a smaller and lighter mini drone housing provides longer battery life and longer range or flight time. Unique rigging validated with casting process simulation gives the confidence of getting complex castings right the first time.

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