Topic: Replicating a UAV.

[Nemesis]

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An unmanned aircraft made from "printed" parts rather than traditional machine-tooled components has been unveiled at the Farnborough Air Show, UK.

Developed at Lockheed Martin's top-secret "Skunk Works" research facility in Palmdale, California, US, the Polecat unmanned aerial vehicle (UAV) is a 28-metre flying wing, weighing four tonnes. It was designed in part to test cheaper manufacturing technologies.

In rapid prototyping, a three-dimensional design for a part - a wing strut, say - is fed from a computer-aided design (CAD) system to a microwave-oven-sized chamber dubbed a 3D printer. Inside the chamber, a computer steers two finely focussed, powerful laser beams at a polymer or metal powder, sintering it and fusing it layer by layer to form complex, solid 3D shapes.

About 90 per cent of Polecat is made of composite materials with much of that material made by rapid prototyping.

"The entire Polecat airframe was constructed using low-cost rapid prototyping materials and methods," says Frank Mauro, director of UAV systems at the Skunk Works.