Bayonet Airframe Fastening for Reconfigurable UAV Assembly

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Solution Overview

Problem

Existing aerial vehicle designs face challenges with rapid changes in mission and payload requirements, lengthy development timelines, and technological advancements outpacing design capabilities, leading to high costs and inefficiencies.

Innovation Solution

A specialized fastening system integrated with airframe components using a bayonet mount system, allowing toolless assembly through passageways and protrusions, and a locking assembly with deflection tabs and slots for secure connection of airframe sections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If traditional aerial vehicle designs are used with fixed components and assembly methods, then structural integrity is maintained, but adaptability to changing mission requirements deteriorates

Engineering Contradiction:

Improveadaptability to changing mission requirementsVSAvoiddesign complexity for rapid reconfiguration

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The aerial vehicle is divided into modular airframe sections that can be independently manufactured and reconfigured. Each section contains integrated fastening features that enable quick assembly and disassembly, allowing the vehicle to be adapted for different missions by reconfiguring the modular segments without requiring complex design changes.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The fastening system transitions from static permanent connections to dynamic reversible connections. The bayonet-style fasteners with deflection tabs allow sections to be quickly connected and disconnected, enabling the airframe to dynamically reconfigure for different mission requirements while maintaining structural integrity during operation.

Inventive Principle:

Principle #15Dynamics

2Productivity

If conventional manufacturing and assembly methods are used, then production quality is controlled, but assembly time and productivity deteriorate

Engineering Contradiction:

Improveassembly speedVSAvoidalignment precision of airframe sections

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

Fastening features including passageways, protrusions, and deflection tabs are pre-integrated into the airframe sections during additive manufacturing. This preliminary integration of fastening elements eliminates the need for separate alignment and fastening operations, enabling rapid assembly while maintaining precision through the pre-configured geometric features.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The bayonet fastening system is designed to self-align and self-lock during assembly. The deflection tabs automatically engage with corresponding slots when sections are connected, providing self-aligning functionality that maintains manufacturing precision without requiring external alignment tools or complex adjustment procedures.

Inventive Principle:

Principle #25Self-service

3Adaptability or versatility

If additive manufacturing is used for airframe sections, then manufacturing flexibility and adaptability improve, but structural integrity and connection strength may deteriorate

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidconnection strength of fastening features

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The fastening features are merged with the airframe sections as single integrated components manufactured through additive manufacturing. The bayonet fasteners, passageways, and deflection tabs are created as integral parts of the airframe sections, ensuring that connection strength is equivalent to the base material and eliminating weak points associated with separate fastening components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The additive manufacturing process parameters are optimized to ensure that the fastening features achieve the same or superior mechanical properties as the base airframe material. By controlling build orientation, infill patterns, and post-processing parameters, the connection strength of the integrated fastening features is maintained at levels suitable for flight loads while preserving manufacturing flexibility.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS12486017B2Additive manufactured integral fastening system for mission adaptable unmanned aerial vehicles

Publication Date: 2025.12.02 FIRESTORM LABS INC

AI summary

Disclosed are specialized airframe structures for mission-adaptable unmanned aerial vehicles (UAVs) that are fabricated by rapid, low-cost additive manufacturing techniques. In some embodiments, an integral fastening system for a mission-adaptable aerial vehicle includes a first airframe section, a second airframe section, and a bayonet mount system that comprises one or more passageways produced on a first end region of the first airframe section to include a first channel and second channel, and one or more protrusions produced on a second end region of the second airframe section, such that, when the first and second airframe sections being assembled, the one or more protrusions are first aligned with an entry region of the first channel to be translated and then aligned with the second channel of the one or more passageways to be rotated to securely connect the first and second airframe sections together.