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When lightweight Construction learns to fly

Fly lighter with FDR Technology

Festo's BionicBee mimics the swarming behavior of bees and provides insights into autonomous flight. Thanks to generative design, lightweight construction, and 3D printing, the artificial bee weighs only 34 grams. 1zu1scale created the lightweight, flexible, and stable frame weighing just 3 grams using high-precision FDR technology.

Autonomous flight, generative design, simulated swarm behavior: Festo is pushing the boundaries of automation technology with visionary projects. We contribute our expertise as 3D printing specialists and exploit the full potential of the technology.

Stefan Rädler,Division Manager Additive Manufacturing

Framework for autonomous Swarm Flying

The BionicBee frame forms the supporting structure of the flying object. With ultra-light struts made of PA11, it ensures stability, flexibility, and robustness for autonomous swarm movements.

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Components

20 cm components with 0.9 mm thin struts

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Properties

Weight only 3 grams – extremely light with high stability

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Scaling

20 copies for Hannover Messe

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Additional Services

High-precision manufacturing with 3D printing SLS-FDR

SCALE: One Process, many Advantages

Sketch

Define requirements

  • Support the project from the first prototype to series production
  • Goal: optimal fit, stability, and function

Check

Iteratively optimize prototypes

  • Iterative optimization of the support frame during the prototyping phase
  • Ensure robustness and functional reliability

Approve

Design finalized & approved

  • Use of FDR 3D printing for ultra-fine, robust structures
  • PA11 material selected for high elongation at break and flexibility
  • Design freeze: validated, reproducible component

Launch

Series production prepared

  • Setup of on-schedule series production
  • Ensuring stable frames and flawless surfaces

Execute

Scalable series implemented

  • Exact reproduction of 20 copies initially
  • Easily scalable to larger quantities
  • Result: efficient, reproducible production for swarm flight or comparable applications

A result that is impressive

Together with Festo, 1zu1scale created the ultra-light BionicBee frame with record-breaking precision. Weighing just 3 grams, the structures enable autonomous swarm flight, mechanical stability, and flexibility, demonstrating the capabilities of FDR technology in 3D printing large, delicate components.

Innovations can only succeed with reliable partners. This is demonstrated by our Bionic Learning Network and also proven by our collaboration with 1zu1scale. The highest quality, adherence to deadlines, and good communication go hand in hand and ensure the success of the project.

Mattias-Manuel Speckle,Head of Additive Manufacturing Prototyping, Festo

Questions & Answers


Enables absolute geometric freedom, combines multiple functions, reduces weight and components.

FDR uses PA11, which is tougher and more flexible than PA12, allowing for complex structures and more stable filigree parts.

0.9 mm thin struts, 20 cm component, only 3 grams.

Iterative optimization, close coordination, precise manufacturing, and control of mechanical properties.

20 units in time for the Hannover Messe 2024 trade fair.

Manufacture of the frame component using FDR technology, quality assurance, and on-time delivery.


Project Managers

From idea to series: The people behind the project.


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