Ultra-lightweight carbon fibre/Kevlar storage case to aid transport and deployment of battlefield UAS

Ultra-lightweight carbon fibre/Kevlar storage case to 

aid transport and deployment of battlefield UAS

The ultra-light carbon fibre/Kevlar UAS case designed by Carbon by Design is designed to allow combatants in the field to achieve the lowest possible weight of deployed systems when combined with today's ultra-light drones. The case was successfully implemented to transport an 8lb UAV using a case weighing only 15lbs.

By significantly reducing weight compared to the company's closest competitor's product, this ultra-light carbon fibre/Kevlar UAS flight system case allows operators to load more systems onto the transport aircraft and effectively reduces field fatigue when operators must make extensive treks to forward camps.

The standard Carbon by Design case weighs less than 6 lbs. This compares to the resin-infused moulded enclosure used by its closest competitor, which weighs 13.5 lbs. The enclosure is made from a combination of carbon fibre and Kevlar to achieve the lowest density per square inch. Each enclosure is individually moulded using a proprietary high-pressure moulding technique and cured at high temperatures for field use at temperatures in excess of 250°F.Standard options for the basic configuration include: EPDM waterproof seals, MIL-SPEC hinges, pressure relief valves, latches and MIL-SPEC spring handles. The liner unit includes a unique protective lip to prevent accidental seal damage in the field. The hinge and latch are protected by a one-piece integrated rib, which allows the housing to be placed on edge without damaging the housing hardware.

Each case has an integrated stacking feature that allows multiple cases to be stacked vertically for easy storage. The interior of the case can be customised and configured for many different mission scenarios. Basic interior options include PU foam, EPP foam, EPE foam and even a Supercor® liner. Foam interiors can be custom cut and moulded to suit individual customer requirements. For larger ISR gimbals, critical instruments and any very valuable contents, Supercor® liners are highly recommended.

Several unique design features have been integrated into the case design specifically designed to support the electronic needs of today's warfighter. Each case includes a channel that extends along the circumference of the lid and base to allow for cable routing without encroaching on internal space. Cases requiring the loading of sensitive or special equipment are available with unique nickel and silver plated enclosures and conductive scratch seals. The contents in this configuration will see an additional 68db of EMI attenuation at 1GHZ. Instead of paint or heavy integrated copper mesh, this special coating is a 2µ layer of nickel and silver plating that adds less than 20g to the total weight of the enclosure.