Metal 3D Printing Enables Lighter and More Efficient Drone Motors at Acodyne

The Danish company Acodyne, in collaboration with the Danish Technological Institute (DTI), has optimized the rotor blades of its electric drone motors using metal 3D printing as part of a MADE project. By employing additive manufacturing, the company was able to significantly reduce both weight and material use, improving the performance of its transport drones.

Acodyne develops electrically powered ducted fan engines—known as Electric Ducted Fans—which function as electric jet engines. These systems are used in large cargo and utility drones capable of transporting payloads of up to 200 kilograms to remote locations such as offshore wind farms or oil rigs. Such applications place high demands on propulsion efficiency, durability, and weight optimization.

“With metal 3D printing, we have reduced the weight of the blades by 30 percent. This weight reduction has cascading effects, which can lead to an overall weight saving of 1-2 kg on the motor’s fan disk, improving both the speed and response time of our products and giving us a significant competitive advantage”, said Claes Nicolajsen, CTO at Acodyne.

“As we scale production—and as metal 3D printing becomes more widespread—we expect the price per unit to decrease further, making the technology even more cost-effective”, said Claes Nicolajsen, CTO at Acodyne.

The DTI handled the technical implementation and optimized the existing rotor blade geometry without altering its external shape.

“We expected that with metal 3D printing, we could significantly reduce the weight of our blades. At the same time, 3D printing gives us the flexibility to quickly adapt and develop new designs, which is crucial for a company like ours that is constantly evolving our products” says Mads Schnack, CEO at Acodyne.

“We redesigned the blades, made them hollow, and added internal ribs, which was necessary to maintain strength and stability. The blades were printed in titanium, which is a light and strong material. With these changes, we managed to reduce the overall weight without compromising the blade’s structural integrity, says Magdalena Susanne Müller, consultant at the Danish Technological Institute, adding:”3D printing allowed us to implement a design that would have been difficult to manufacture using traditional methods. The result is a lighter component that can still withstand the forces it is subjected to at high speeds.”

Through additive manufacturing, Acodyne achieved a design that would be nearly impossible with conventional methods. Each blade is approximately 90 grams lighter, resulting in a total weight reduction of up to one kilogram per motor. This reduction enhances both the drones’ energy efficiency and control precision. Acodyne sees this as an important step in further developing its technology and securing a long-term position in the market.