The circuit is one of over fifty supplied by Trackwise into this vehicle. The entire interconnect system (power and signal) of the vehicle is made of FPCs representing an estimated total systems weight saving of 60% over traditional wire harness, according to the company. This will enable the UAV, which is being manufactured in the US, to achieve higher payload and/or improved speed and range. The FPCs are manufactured using Improved Harness Technology (IHT), a patented, reel-to-reel manufacturing technique. Conventional FPCs are rarely more than two metres in length, primarily due to limitations of manufacturing processes. IHT overcomes these limitations, enabling FPCs of unlimited length to be produced.
The UAV’s flexible circuit is based on a polyimide substrate. The planar structure of the circuit dissipates heat better than conventional wiring, enabling higher current carrying capacity for a given weight of copper conductor. Printed manufacturing ensures circuit consistency, fewer connection points are needed so reliability is enhanced, and the FPC is easier to install than wire harnesses, reducing a vehicle’s assembly time and cost.