1 repurposing surplus unmanned aircraft systems into uas platforms for science missions

This reports the preliminary results of a multidisciplinary project conducted at the NASA Ames Research Center (ARC) involving a number of student interns over the summer of 2014. The project had a goal of applying rapid prototyping techniques including 3D printing to unmanned aircraft systems (UAS), and demonstrate that surplus UAS could be repurposed into new configurations suitable for conducting science missions. In 2012, NASA ARC received several units of the RQ-14 DragonEye manufactured by AeroVironment Corporation, along with their ground stations and spare parts. These UAS have dual electric propulsion, a wingspan of 1.1 m, a length of 0.9 m, and a nominal weight of 2.7 kg in stock configuration; they are designed to disassemble for transport, have a simple wing design (rectangular with no twist), and are made from lightweight materials. A dozen of these aircraft were prepared by removing all ITAR restricted technology (e.g. autopilot, documentation, etc.) and then provided to three teams of summer interns that also had access to 3D printing, CNC hot-wire foam cutting, and CNC laser-cutting equipment through NASA’s SpaceShop. The modular nature and simple wing profile of the RQ-14 enabled the teams to deconstruct and subsequently reconfigure them into completely new airframes. Two teams proposed multi-fuselage designs using Ardupilot-based common avionics architecture (CAA), with extended wingspans, a horizontal tail and an innovative cambered flap system. After NASA internal design reviews, the students fabricated new control surfaces and subcomponents necessary to splice the RQ-14 subcomponents back together. Laboratory testing was performed on test articles to determine Young’s bending modulus and safety factors, and documentation was prepared for airworthiness flight safety review. A separate team conducted tests on the consistency of construction and durability of materials. Upon receiving approval of documentation and flight readiness certification, the repurposed UAS were flown at Crows Landing airfield in Stanislaus County,