HEAVY LIFT DRONE
Explanation
The structural battery is the mechanical and electrical spine of the drone. It strengthens the airframe to stop the arms ‘bending’ out of limits and making the aircraft unstable in flight and crashing.
Technical detail:
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400V 7.5 kWh structural battery pack using Molicel P42A cells (5p100s)
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Parallel hybrid power system (gas turbines and battery pack) – this was battery only flight test
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Orion 2 BMS for prototype - intention to build-in our own BMS for production
Mass Equivalent Calculations
50% weight saving - how we calculated that
Establishing the weight saving benefits of a structural battery to the heavy lift drone:
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By establishing the torsional stiffness of the structural battery, we can compare to other airframe designs and materials.
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The drone battery mass is 49kg including BMS, contactors, wires etc.
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An aluminium box section, with identical torsional stiffness has a mass of 52kg
Using a traditional airframe plus battery = 101 kg
Structural Battery including it as the airframe = 49 kg (~ 50% saving)
Flying Heavy: How DASA-funded UAS Revolutionises Military Logistics
With the help of DASA funding, ISS Aerospace developed a 600kg heavy-lift unmanned aerial system capable of carrying 250kg payloads.
The innovation features a unique hybrid turbine generator power system that eliminates the need for complex electrical recharging infrastructure in the field.
DASA's Defence Technology Exploitation Programme (DTEP) provided critical funding that enabled ISS to create this technology.
Successfully trialled in 2025, this project represents the first completed DTEP project.
