Sean Headrick of AeroTestra produces sUAV’s for use in photogrammetry (surveying land), imaging for crop analysis by utilising near IR imagery, and many other remote sensing applications. All of the parts on these flying machines are formed with either a 686 or FLB500.

Sean makes use of both of these machines at TechShop in San Jose, where he was also able to cut low cost MDF tooling utilising their ShopBot CNC’s. The materials utilised for these particular sUAV’s are a high-impact polymer in conjunction with Kydex.

As a member of TechShop Sean utilised the 686 and FLB500 on site to bring his designs to fruition. After experimenting with the home oven method he quickly realised that this design would definitely take a more professional machine. After two years of honing Sean’s craft on the 686 he is now considering a larger Formech machine to scale up the design.

Most sUAV enthusiasts were building machines out of existing materials like wood, carbon fiber, and aluminum. Sean had an ‘ah-ha’ moment while handling an old balsawood airplane with a vacuum formed canopy for a related project he was considering.

Sean quickly mastered the art of thermoforming utilising the Formech 686. His designs are some of the most innovative we’ve seen on this manual machine!

In Sean’s words – “Well thought out, the 686 easily provides consistent results. It is a simple machine and therein lies its strength. Also, the FLB is very easy to use and bends the Kydex with ease, the operation is very intuitive. Formech’s machines do exactly what a professional grade tool is meant to do.

After a very short learning curve I was able to create a system in order to achieve repeatable results. Originally I set out to make a very simple construction but I quickly realised that almost every aspect of my unmanned aircraft could be made on the Formech 686 and FLB500.” In a nutshell these are easy to use tools that really help bring out a skillful designer’s capabilities.

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