Improving manufacturing techniques to minimize costs have always been the ultimate goal for engineers since the dawn of technology. Working toward making the end product as affordable as possible without compromising on its quality is not just a skill set to develop but also, art. This thesis deals with changing the approach to the manufacturing of the patented XQ-139 UAV by using alternative materials to reduce production costs and time. Retaining the overall structure and utility of the UAV while eliminating the high costs to produce is the primary goal. It also includes tests performed on the new UAV airframe to prove this hypothesis and compare it to the results of the original airframe. The objective is to prove that the new airframe can cope with the structural and performance demands of the original XQ-139A, while reducing the total costs to manufacture it. This thesis only deals with the processing and manufacturing of the new XQ-139A airframe. No flight tests are involved.
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