Custom Carbon Fiber Tubes for Drones
— Ultra‑Light · High‑Strength · Integrated Solutions
Author: Aohong Aerospace‑Grade Carbon Fiber R&D Center
1. One‑Sentence Value Proposition
Our carbon fiber tubes are 55% lighter than aluminum and 2.3× stronger than titanium, converting every gram into 15 extra minutes of flight time.
2. Key Challenges in Drone Frames
- Generic tubing issues: Single wall thickness, loose tolerances → requires in‑service counterweights.
- Arm resonance: Traditional tubes have low torsional stiffness → PID tuning is difficult.
- Extreme temperatures: Thermal expansion/contraction of metal tubes causes joint‑spacing drift → degrades RTK accuracy.
Solution: We deliver fully customized carbon fiber tube assemblies (tube body + interfaces + wiring channels) that are 100% compatible with your flight controller and powertrain.
3. Core Technical Specifications
| Parameter | Typical Value | Available Range |
|---|---|---|
| Outer Diameter (Φ) | 10 / 15 / 20 / 25 / 30 mm | 4–60 mm |
| Wall Thickness (t) | 0.8 / 1.0 / 1.5 mm | 0.3–5 mm |
| Linear Mass | 38 g/m (Φ20×1.0 mm) | Down to 12 g/m |
| Tensile Modulus | 135 GPa (T300) / 160 GPa (T800) | Upgradeable to M40J |
| Bending Stiffness | 3.8× that of 7075‑T6 | — |
| Torsional Stiffness | 5.2× that of 7075‑T6 | — |
| Straightness | ≤ 0.1 mm/m | Precision grade ≤ 0.05 mm/m |
| Operating Temperature | –40 °C to +120 °C | Low‑/high‑temp resin options |
4. Customization Options
A. Fiber System
- T300 Standard: Cost‑effective, stable supply—ideal for large‑volume agricultural drones.
- T800 Aerospace: 20% additional weight savings—perfect for high‑altitude, long‑endurance UAVs.
- M40J High Modulus: 35% wingtip deflection reduction—suited for mapping and LiDAR drones.
B. Layup Strategy
- 0°/±60° for torsion resistance: Suppresses arm vibration.
- 0°/90° for bending strength: Prevents landing‑impact fractures.
- Embedded UD ribs: +0.2 mm local thickening—directly mounts motor base, no metal sleeve needed.
C. Integrated Interfaces
- Molded-in aluminum/titanium sleeves: ± 0.02 mm tolerance; press‑fit assemblies with no adhesive.
- Internal wiring channels: Separate compartments for ESC power, GPS coax, network cable—optimized EMC.
- Quick‑release dovetail: 3 s arm removal, 1 s lock‑in; repeatability ± 0.05 mm.
D. Surface & Markings
- Matte black: Anti‑glare for reconnaissance and inspection drones.
- 3K twill glossy: Brand showcase and FPV racing rigs.
- Laser‑etched scales: Rapid field balancing and measurement.
5. Measured Performance (Φ20×1.0 mm Tube)
- Three‑point bending: 1,850 N ultimate load, 4.8 mm deflection
- Torsion test: 35 N·m torque → 1.2° twist, no delamination or noise
- Fatigue test: ± 550 N, 2 million cycles no damage (aluminum fails at 450 k cycles)
- Thermal cycling: –30 °C & +80 °C for 8 h each → axial drift < 20 µm
6. Example Drone Configurations
| Drone Type | Tube Spec | Weight Saved | Flight Time Gain |
|---|---|---|---|
| 5 kg Quadrotor Sprayer | Φ25×1.5 mm × 4 tubes | 320 g | +7 % |
| 2 kg Hexacopter Mapping | Φ20×1.0 mm × 6 tubes | 210 g | +11 % |
| VTOL Fixed‑Wing Wing Spar | Φ30×2.0 mm × 2 tubes | 450 g | +15 % |
Optimize Your Carbon Fiber Solution
Whether you need custom carbon fiber tubes, rods, sheets, precision CNC machining, or prepreg layup, our structural engineering team will craft the optimal solution balancing strength, weight, and cost.
7. Manufacturing & Quality Control
- Automated Fiber Winding (AFW) + Autoclave Cure: Wall‑thickness tolerance ± 0.05 mm
- Laser Projection Layup: ± 0.2° angular precision
- 100 % Go/No‑Go Gauges + Ultrasonic C‑Scan: Zero porosity guarantee
- Dynamic Balance Report: Supplied with every batch—no tuning required at installation
8. Rapid Delivery
- Standard Sizes: Prototypes in 48 h, small runs in 7 days
- Custom Designs: Upload STEP/IGES—DFM report in 1 h
- Branding Options: Color options, logos, QR‑code laser marking for brand recognition
9. Get Your Tailored “Ultra‑Light High‑Strength” Tube in 30 s
Upload your UAV payload & arm‑spacing, and receive a customized carbon fiber tube selection sheet instantly.
Every gram counts—fly farther with XXX’s industry‑leading carbon fiber tube solutions.
