Project Overview

The Gyrotrak™ hybrid UAV system was developed collaboratively by RotoJet Hungary Kft and Airial Robotics in Hamburg, Germany. The project focused on creating a versatile drone platform capable of extended flight times, heavy payload capacities, and operational reliability across diverse commercial applications such as surveillance, logistics, agriculture, and infrastructure inspection. Our role centered on the design phase and manufacturing of composite components, contributing to a drone optimized for performance, safety, and regulatory compliance.

Process Planning

The development of the Gyrotrak™ system began with integrated aerodynamic and structural design. Iterative simulations optimized lift, drag, and stability under varying conditions. The modular concept allowed multiple payload configurations ranging from 4 kg to 20 kg, ensuring adaptability for different missions. Our design work translated directly into the composite elements, with every iteration carefully engineered for stiffness, weight optimization, and manufacturability. Safety features and operational redundancies were incorporated at every stage.

Manufacturing

The composite components were produced in pre-preg, hand-laid using aerospace-grade materials to achieve a lightweight yet highly rigid structure. Vacuum-bagging and controlled curing ensured structural integrity and precision fitment. The resulting UAV components were integrated with the full system, providing a high-performance platform capable of extended endurance and heavy-lift operations, setting a benchmark in hybrid drone technology.

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