Taking Cleaning to New Heights: How Additive Manufacturing Enables High-Performance Drone Solutions
Drones for Industrial Cleaning
Maintaining the pristine condition of building facades, expansive glass surfaces, and large-scale solar installations presents a constant operational challenge. Traditional methods, relying on scaffolding, hydraulic lifts, or rope access, making them labor-intensive and time-consuming while posing significant safety risks to workers. In the search for a safer, more efficient, and cost-effective alternative, Swiss Drone Services AG envisioned a solution that could rise above these legacy constraints: a specialized drone equipped with a high-pressure cleaning system.
However, turning this vision into a reality was fraught with complex engineering hurdles. The critical link between the drone and the cleaning apparatus — the nozzle and lance — required a unique combination of properties that pushed conventional manufacturing methods to their limits. To solve this, Swiss Drone Services AG partnered with additive manufacturing specialist Ecoparts AG, who leveraged the power and precision of EOS technology to produce a component that was not only functional but met every technical requirement, starting a new era of automated, high-altitude cleaning.
Challenge
The core challenge for Swiss Drone Services AG was to develop a cleaning lance and nozzle assembly that could withstand the rigors of high-pressure water jets while being light enough for drone-based operation. Any excess weight would drastically reduce flight time and maneuverability, compromising the entire business case. The component needed to be exceptionally stable, as the combined vibrations from the drone’s powerful rotors and the high-pressure cleaner could create a cascade of problems — from rendering the drone uncontrollable to causing long-term structural damage to its sensitive frame and electronics.
Furthermore, the project demanded a high degree of customization to optimize the cleaning process for different surfaces and conditions, while tight deadlines pressured the development team. A conventionally manufactured solution would have likely involved a multi-part assembly of milled and welded components. Such an approach would have been heavier, introduced potential points of failure at the joints, and offered little capacity for vibration damping. The design and fabrication process would have been too slow and rigid to meet the project's ambitious timeline and performance goals. Swiss Drone Services needed a manufacturing approach that could deliver a lightweight, robust, and highly customized component quickly — a combination of requirements that traditional methods simply could not fulfill.
Customized
Commercial drone with a customized payload ensures optimized cleaning efficiency.
Lightweight
Weight-saving bracket for holding a high-pressure cleaning lance maximizes light time.
Stable
Brackets must fix the lance without transferring vibration to maintain flight stability.
Solution
Ecoparts AG, a leader in producing high-quality metal 3D-printed parts, employed its EOS M 290 system to fabricate the custom lance and nozzle. The material of choice was EOS Aluminum AlSi10Mg, an alloy renowned for its excellent strength-to-weight ratio and thermal properties, making it ideal for demanding aerospace and industrial applications.
Leveraging the capabilities of DMLS, Ecoparts’ engineers were able to design a monolithic, topologically optimized component. This process allowed them to consolidate what would have been a complex assembly into a single, seamless part. Internal channels and complex geometries were integrated directly into the design, creating a fluid path for the high-pressure water while using material only where it was structurally necessary.
This approach drastically reduced the component's final weight while maximizing its rigidity. The EOS M 290, processing the aluminum powder in precise 60 µm layers, ensured the final part was strong while meeting the exact specifications for a perfect fit and optimal fluid dynamics. This rapid, toolless production method enabled fast design iterations, allowing the team to test and refine the component to perfection, successfully meeting the tight project deadline.
"This project is a perfect example of what metal 3D printing is all about. We were faced with a set of conflicting requirements — low weight, high strength, vibration resistance, and a complex geometry. With the EOS M 290, we could produce a functionally integrated, high-performance part that would be nearly impossible to machine as a single piece, solving the client's core manufacturing challenge."
Daniel Kündig, Ecoparts AG
Results
The collaboration between Swiss Drone Services AG and Ecoparts validated the role additive manufacturing will continue to play in the development of advanced robotics. The 3D-printed aluminum lance and nozzle assembly met and exceeded all performance criteria, directly enabling the commercial launch of the new cleaning drone service.
The most significant outcome was achieving the perfect balance of low weight and high stability. The final component was significantly lighter than any feasible machined alternative, achieving a 40% weight reduction and directly translating to longer flight times and greater operational range for the drone.
The monolithic design proved exceptionally robust, easily withstanding the forces of the high-pressure cleaner.
This superior vibration damping, which reduced peak vibrations at the drone mount by over 60%, protects the drone's main body and ensures it remains stable and easy to maneuver during cleaning operations. Meanwhile, the rapid development cycle afforded by the EOS M 290 platform reduced the concept-to-final-part timeline from months to weeks, with the final component delivered in just 3 weeks from the initial design. Swiss Drone Services AG is now equipped with a cutting-edge, highly efficient cleaning solution that offers a safer and more scalable alternative to traditional methods, giving them a distinct competitive advantage in the market.
- 40 % weight reduction to maximize flight time and agility
- 60 % peak vibration reduction for increased flight stability
- Met aggressive project timelines with a 3-week concept-to-part delivery
- Custom bracket design optimizes cleaning efficiency and reduces water usage
"The operational stability of our cleaning drone was our top concern. The vibrations from the high-pressure system are intense. A traditionally assembled part would have introduced too many failure points and wouldn't have given us the stiffness we needed. Additive manufacturing with EOS technology was the only way to get a component that’s light but also stiff enough to absorb those forces, making our system commercially viable."
Marco Bortolan, Management Technology / Development, Swiss Drone Services AG
About the Companies
Swiss Drone Services AG
An innovative service provider specializing in the development and operation of professional drone systems for industrial applications, including cleaning, inspection, and surveying. Learn more: https://swiss-drone-services.ch/en/
Ecoparts AG
A leading Swiss provider of industrial 3D printing services, specializing in the production of high-quality metal components for a wide range of industries, from motorsports to aerospace. Learn more: https://ecoparts.ch/
