Ukrainian company POLIFLY is revolutionizing UAV manufacturing by replacing traditional composites with high-quality polyurethane. Showcased at the Brave1 Components exhibition, their flagship drone, “Cooper”, promises to meet the three critical demands of modern warfare: low cost, high efficiency, and rapid scalability.
The Material Revolution
The core innovation lies in the transition to polyurethane technology. According to POLIFLY, this shift addresses the limitations of standard materials. The new polyurethane bodies are 19% lighter than their three-component composite counterparts without sacrificing structural integrity.
“The material proved not only cheaper than three-component composites but also lighter… while maintaining strength”, the developers noted.
Beyond weight reduction, the technology simplifies the assembly process significantly. Technical openings for cameras, warheads, or batteries are formed directly during the molding process. This reduces manual labor and accelerates production times.
Meet the “Cooper”
The flagship of this new line is the Cooper attack drone. Built with a reinforced polyurethane body, it features an aerodynamic design similar to the “Shahed” loitering munition and utilizes a rear pusher motor.
Key Technical Specifications:
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Wingspan: 1.2 meters.
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Combat Range: Over 90 km.
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Payload Capacity: Up to 5.5 kg.
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Warhead Options: Thermobaric, HE-fragmentation, or cumulative.
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Launch System: Catapult-launched.
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Navigation: Autonomous flight via autopilot and GPS.
The drone is designed for seamless integration into existing infrastructure. It functions with a ground control station capable of operating up to 35 km without external communication channels.
Industrial Scalability
The most significant advantage of the POLIFLY approach is the speed of manufacturing. The company highlights that polyurethane technology allows for mass production rates that dwarf classic composite methods.
“With just three sets of matrices, it is possible to produce up to 700 bodies per month—four and a half times more than with the classic composite scheme”, the company stated.
Currently, available production capacities allow for the manufacturing of up to 200 bodies per month. With lower costs, higher repairability, and rapid assembly, the Cooper drone represents a scalable solution for supplying the front lines with essential strike capabilities.
Source: MILITARNYI