Precision Lubrication

Modern UAVs include numerous moving parts—rotors, gimbals, linkages, and landing gear—that must operate with minimal friction under various loads and weather conditions. In these small-format mechanical systems, precision lubrication is vital. However, excessive lubrication can contaminate surrounding electronics or create dirt-attracting buildup, while insufficient lubrication leads to accelerated wear and system failure. Automated spray systems from Spraying Systems Co. offer the accuracy needed for reliable and efficient lubrication in drone manufacturing.

Common Challenges Solved:

• Lubricant Migration or Overspray: Inaccurate targeting of lubricant can lead to contamination of nearby optics, wiring, or circuit boards.
• Insufficient Lubricant on Critical Contact Points: Under-lubrication can result in premature failure of gimbals, actuators, or gears.
• Inconsistent Application Between Units: Manual oiling introduces significant variability in coverage and performance between production batches.
• Excessive Mist or Drip Formation: Air atomizing systems often create fine mists that settle beyond the intended area or result in airborne residue.
• Excessive Consumption and Waste: Lack of control over droplet volume leads to unnecessary material use and maintenance costs.
• Materials Used: Lightweight oils, synthetic lubricants, greases, anti-friction coatings.

Sensor Coating & Functionalization

Drone sensors, such as cameras, LiDARs, and infrared detectors, require optically clear, protective coatings that must be applied with high accuracy. Even minor overspray or inconsistent thickness can degrade image quality, alter signal transmission, or compromise calibration. Spraying Systems Co. provides precision spray technologies for applying these specialty films.

Common Challenges Solved:

• Coating Inconsistency on Lens and IR Surfaces: Uneven coatings can distort vision or reduce infrared transparency.
• Overspray onto Surrounding Assemblies: Poor spray control can result in materials reaching motors, housings, or internal electronics.
• Clogging or Buildup at Nozzle Tip: Thin-film chemistries may dry quickly, necessitating anti-bearding or clean-out features.
• Excessive Rework or Part Rejection: Quality failures from poor functionalization can lead to scrapped high-value sensors.
• Limited Control of Film Thickness: Spray systems that lack modulation or pressure control often apply too thick or thin a layer.
• Typical Spray Pattern: Ultra-narrow or circular patterns with high transfer efficiency.
• Materials Used: Optical coatings, moisture barriers, anti-fog treatments.

Thermal Management & Cooling

Compact electronics and battery modules in drones are prone to heat buildup—especially in autonomous or long-duration flight systems. Maintaining safe operating temperatures is essential for flight reliability, sensor accuracy, and battery longevity. Traditional cooling methods often lack precision or introduce condensation risks. Fine spray-based thermal management systems from Spraying Systems Co. deliver localized misting solutions with high repeatability and surface control.

Common Challenges Solved:

• Hot Spots on Circuit Boards or Batteries: Uneven heat distribution can cause critical component degradation or shutdown.
• Condensation Risks: Improper misting or pooling of coolant fluids can cause shorts or corrosion on sensitive electronics.
• Overcooling or Energy Waste: Systems without controlled flow rates may exceed thermal requirements, wasting water or increasing energy use.
• Inconsistent Cooling Across Varying Loads: Systems unable to adapt to real-time conditions may underperform during variable workloads.
• Difficulty Integrating Cooling in Sealed Enclosures: Spray systems must function in tight or inaccessible compartments without intrusive airflow.
• Materials Used: Deionized water or dielectric cooling fluids.

Endurance (Loiter Time) & Battery Thermal Management

Flight endurance is driven by both efficient propulsion and stable battery temperatures. The application of thin, protective films helps propellers and leading edges retain aerodynamic smoothness, while precision spray-based cooling helps maintain cells at optimal operating temperatures. This combined approach can support longer loiter times without requiring major hardware changes.

Common Challenges Solved:

• Thrust loss from rain/particle erosion or icing on propellers and leading edges.
• Hot spots at cell tabs/end caps and large cell-to-cell temperature imbalance.
• Condensation and pooling risks associated with uncontrolled cooling methods.
• Thermal throttling that shortens flight time, especially under sustained load.
• Integration limits where airflow is constrained or enclosures are sealed.

Additive Manufacturing & Support Removal

Additive manufacturing techniques, such as Fused Deposition Modeling (FDM) and Stereolithography (SLA), are frequently used in drone production for structural prototypes, fixtures, and even final components. These parts often contain support materials or internal voids that require delicate removal. While traditional cleaning methods risk damaging fragile geometries or are labor-intensive, spray-based support removal provides even, effective coverage with minimal manual handling, ensuring fast turnaround and quality finishes.

Common Challenges Solved:

• Incomplete Support Removal in Complex Parts: Manual rinsing may miss supports in cavities or internal channels.
• Damage to Delicate Features: Brushing or high-pressure water streams can deform thin walls or unsupported surfaces.
• Operator Variability: Manual cleaning processes introduce inconsistencies in finish quality and throughput.
• High Water Consumption: Inefficient spray systems can waste water and raise operating costs.
• Downtime from Clogged Rinse Nozzles: Solvents or suspended solids from support material can clog spray nozzles if not selected properly.
• Materials Used: Water, solvent-based support material removers (as compatible with nozzle material).

Structural Integrity: Nanomaterial Deposition for Composites

The spray deposition of ultra-low-mass nanomaterial dispersions (e.g., carbon nanotubes, graphene nanoplatelets) at ply interfaces or onto carbon fibers can enhance interlaminar toughness and impact resistance without meaningful weight gain.

Common Challenges Solved:

• Delamination risk in thin Carbon Fiber Reinforced Polymer (CFRP) skins and spars.
• Toughness loss around cutouts and fastener-free joints.
• Variability resulting from hand-applied films or wipes.
• Typical Spray Pattern: Narrow flat spray or circular pattern; targeting 20 to 70 micron droplets for fiber wetting without run-off.
• Materials Used: Carbon Nanotube (CNT)/Graphene Nanoplatelet (GNP) dispersions in water or compatible solvents; coupling agents matched to epoxy/cyanate-ester systems.