The Problem
A commercial drone manufacturer needed a custom mounting bracket to integrate a highly sensitive new sensor payload. Standard off-the-shelf mounts were too heavy and transferred too much high-frequency motor vibration to the sensor, rendering the data completely unusable.
The Challenge
The mount had conflicting physical requirements and an incredibly tight schedule:
The Solution
We proposed and manufactured a hybrid assembly that played to the strengths of both CNC machining and 3D printing.
- ✓Hybrid approach: Machined the core structural bracket from lightweight Aluminum 7075 for rigidity, paired with custom 3D printed TPU (flexible) inserts to act as dampeners.
- ✓Rapid fabrication: Pushed both the CNC routing and TPU printing streams in parallel, completing manufacturing within 48 hours.
- ✓Vibration optimization: Adjusted the infill density on the TPU prints specifically to absorb the known resonant frequencies of the drone motors.
- ✓CG Alignment: Ensured all mounting points precisely aligned with the drone's center of gravity to maintain stable flight dynamics.
The Outcome
The complete hybrid assembly was delivered in just 3 days. The combination of rigid aluminum and tuned TPU resulted in a ~40% reduction in vibration transfer to the sensor, while staying well within the tight weight constraints. The drone was successfully used in a live investor demo two days later, which directly helped the client secure a new pilot project.