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ROCROW

In 2014, I was asked by the Wingbeat company (www.rofalconry.com) whether I could design a remote-controlled model aircraft that looked like a crow and would serve as a tool for teaching young birds of prey to hunt. Because you can control the model yourself, this makes it a particularly exciting sport for humans and animals. Sounds fantastic, but there were quite a few design requirements:

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  • The model had to resemble a bird as much as possible.

  • He had to be able to survive attacks from a real falcon that hits the model at a speed of over 300 km / h.

  • The design had to be modular so that repairs can easily be done in the field.

  • The model must be able to fly, preferably faster than 80 km / h in horizontal flight and even be controlled by beginners.

  • The model must be able to fly in rain and a storm.

  • It had to be possible to produce the model as cheaply as possible.

  • There must be no sharp parts on the model.

 

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These were just a few requirements, the rest of the requirements such as being able to reach altitudes of 400 meters ore more, being able to fly autonomously, battery protection for impacts etc are requirements I leave aside for a moment. It was a huge challenge but exactly the challenge I love. Multi-disciplinary thinking and implementation. I started with a dead crow. Traced it on paper, scanned, and used this scan as the basis for my 3d drawing. In the initial stage the drawing was used to make the prototype. The prototype is cut from expanded polypropylene on my computer-controlled hot wire cutter using the 3d drawing. The production model is made of the same materials to get the prototype as close as possible to the final product. Plastic parts are 3D printed with an FDM printer and SLS technology. I made the head from PU foam in a silicone mold that is still used by the factory today. The model was equipped with specially selected electronics to fly and survive, and in addition, the model was equipped with GPS to fly autonomously. I made 12 models that were flown in Northumberland, England in severe weather conditions. Rain, storm and wind.

 

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30 birds per day were flown on the model, after which a logbook was kept with the necessary adjustments. Now it was time to fly the model in the Middle East because there would be Wingbeat's biggest market here. Testing was carried out at temperatures over 50 degrees over a period of 2 months. The model was excellent, and some minor adjustments were needed. Now it was time to send the drawings to a suitable company in China. The model itself has approximately 5 foam parts and 10 plastic parts from Nylon and Polycarbonate which were produced over a period of 4 months. In the meantime, I started looking for the electronics. Quality at reasonable prices and interesting delivery times. I also went to work making stickers to make the model look the same. Now that it was set in motion, it was time for one of the final steps; designing a box and lid. Once again there was a decent list of design requirements.

  • The model had to fit in a small box that you can take with you when traveling and is equipped with everythinhad to serve as a work station.

  • When it storms, the model must remain in place.

  • The box must keep all parts in place when it is sent to the customer.

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1100 models have now been produced and sold in more than 18 different countries around the world.

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