Capabilities

Orbital UAV is the world leader in spark ignited, heavy fuel propulsion systems for tactical UAVs.

Orbital UAV provides engine development, testing, validation, production and refurbishment services in world class facilities located in Western Australia and Oregon, USA. With the right combination of academic qualifications and hands on experience across the range of mechanical, electrical and production engineering service areas, customer requirements are taken from concept and definition through to commercialisation and support services by our dedicated in-house team.

Our customers include

Design & Development

Orbital UAV applies a methodical and exhaustive process for engine/component/system design and development, in both the mechanical and electrical/electronic realms

Discrete phases from concept definition through to series production
State-of-the-art analysis tools, including computer-aided engineering/modelling capabilities
Design iteration through prototyping and detailed test procedures, drafting, measurement and analysis
Control system programming/coding and testing processes
Computer based tools and applications
Strict validation processes through all stages:
- Concept
- Prototype
- Design Verification
- Production Validation

This process has been developed and implemented on a wide range of applications.

Machining & Prototyping

Orbital UAV’s in-house manufacturing capability includes:

Rapid in-house manufacture for prototyping and production of engines and engine components, including air compressors and other machine parts
Additive manufacturing (3D printing)
Manual, NC, and computer numerically controlled (CNC) mills/lathes/drills, high precision grinding & honing, to facilitate the machining and fabrication of engine parts and ancillary components.
Electrical and electronics prototyping and manufacture
Metrology laboratory for quality control covering all incoming and machined parts
Developed, world-wide, quality approved, supply base

Product Integration

Orbital UAV’s expertise and continued success in the small tactical UAV class can be leveraged to seamlessly and rapidly deliver propulsion systems for other UAV classes.

The technology and know-how behind Orbital UAV’s propulsion systems and associated proprietary componentry covers a range of key areas, including:

Fuel injection systems
Electrical power systems
Engine/vehicle control systems and strategies
Engine ancillary components and systems
Related system software and firmware

This technology and know-how, whether together or individually as required, can be integrated across a range of engine types (including piston, rotary and hybrid engines), and all engine/vehicle size classes.

Testing & Validation

Orbital UAV applies a rigorous process developed from automotive production experience and optimised for UAV-specific requirements.

Extensive use of scientific, statistical & numerical analysis (virtual development, not hardware development) to optimise:
- Stress
- Heat management
- Flow
- Engine balance
- Vibration
Design validation and production validation plans developed from FMEA and worst-case operating conditions

Test facilities include:
- Fully instrumented engine dynamometer facilities, including durability dynamometer facilities
- Propeller durability test stands to perform FAR 33 paragraph 49 UAV engine durability
- Environmental dynamometers for cold start down to -35C and hot operation up to 60C
- Altitude simulation up to 20,000ft
- Noise vibration harshness (NVH) equipment for intake and exhaust optimisation
- Engine and control system calibration facilities
- Fuel injector and fuel system bench test facilities
- Compressor test stands for flow and durability
- Highly Accelerated Stress Screening

Manufacturing & Production

Orbital UAV operates high quality, dedicated UAV assembly and qualification test lines for our propulsion systems and other products.

ISO 9001 quality accreditation for engine manufacture
Extensive sub-assembly and final assembly end of line (EOL) qualification testing
Complete propulsion system acceptance testing for delivering a validated product to customers
Trained personnel in IPC-A-610 and IPC/WHMA-A-620
Fully automated electronic test jigs and fixtures
ANSI/ESD S20.20 control program

Servicing & Support

Full after-sale service, including servicing, repair and refit with full quality assurance
Facilities available in both Australia and USA
Customer on-site support