Dragonfly’s rotors complete testing
According to a press release yesterday from the Applied Physics Lab (APL) in Maryland that is building the Dragonfly helicopter that is going to Saturn’s moon Titan, the rotors have completed the first round of testing, and are now about to undergo “fatigue and cryogenic trials under simulated Titan conditions.”
Over five weeks, from August into September, the team evaluated the performance of Dragonfly’s rotor system — which provides the lift for the lander to fly and enables it to maneuver — in Titan-like conditions, looking at aeromechanical performance factors such as stress on the rotor arms, and effects of vibration on the rotor blades and lander body. In late December, the team also wrapped up a set of aerodynamics tests on smaller-scale Dragonfly rotor models in the TDT [Transonic Dynamics Tunnel].
This quote about the manufacture of the rotors however stood out the most:
Pennington and team cut Dragonfly’s first rotors on Nov. 1, 2024. They refined the process as they went: starting with waterjet paring of 1,000-pound aluminum blocks, followed by rough machining, cover fitting, vent-hole drilling, and hole-threading. After an inspection, the parts were cleaned, sent out for welding, and returned for final finishing.
“We didn’t have time or materials to make test parts or extras, so every cut had to be right the first time,” Pennington said, adding that the team also had to find special tools and equipment to accommodate some material changes and design tweaks. [emphasis mine]
In other words, this is another hardware-poor NASA project. What they build is what they have. No time or money for testing of prototypes.
This mission is really pushing the envelope, possibly more than any NASA planetary probe in a half century. I just hope they get it right.
According to a press release yesterday from the Applied Physics Lab (APL) in Maryland that is building the Dragonfly helicopter that is going to Saturn’s moon Titan, the rotors have completed the first round of testing, and are now about to undergo “fatigue and cryogenic trials under simulated Titan conditions.”
Over five weeks, from August into September, the team evaluated the performance of Dragonfly’s rotor system — which provides the lift for the lander to fly and enables it to maneuver — in Titan-like conditions, looking at aeromechanical performance factors such as stress on the rotor arms, and effects of vibration on the rotor blades and lander body. In late December, the team also wrapped up a set of aerodynamics tests on smaller-scale Dragonfly rotor models in the TDT [Transonic Dynamics Tunnel].
This quote about the manufacture of the rotors however stood out the most:
Pennington and team cut Dragonfly’s first rotors on Nov. 1, 2024. They refined the process as they went: starting with waterjet paring of 1,000-pound aluminum blocks, followed by rough machining, cover fitting, vent-hole drilling, and hole-threading. After an inspection, the parts were cleaned, sent out for welding, and returned for final finishing.
“We didn’t have time or materials to make test parts or extras, so every cut had to be right the first time,” Pennington said, adding that the team also had to find special tools and equipment to accommodate some material changes and design tweaks. [emphasis mine]
In other words, this is another hardware-poor NASA project. What they build is what they have. No time or money for testing of prototypes.
This mission is really pushing the envelope, possibly more than any NASA planetary probe in a half century. I just hope they get it right.









