Client Overview-Angel Aerial Systems
Angel Aerial Systems has developed an innovative spinning drone capable of up to two hours of hover time—three to six times longer than traditional quadcopters.
Its groundbreaking Trio™ airframe delivers a reliable, continuous aerial surveillance platform purpose built for lifesaving and mission-critical operations.
As a pioneer in next-generation unmanned aerial vehicles (UAVs), Angel Aerial Systems is redefining drone endurance for public safety, defense, and national security missions.
Challenge
During the initial design phase of the Trio airframe, the engineering team encountered significant challenges sourcing bearings that met the stringent size, material, and performance requirements unique to their spinning drone application. Specifically, the team required a broad range of bearing options—including metal, ceramic, plastic, and glass materials—to optimize actuation systems within their drone. The limited availability of suitable components from other suppliers threatened to constrain design flexibility and overall system performance.
Solution
SolutionAngel Aerial Systems partnered with Boca Bearings, recognizing the company’s extensive product portfolio and ability to provide bearings in custom sizes and diverse materials. Boca Bearings’ broad selection proved invaluable, furnishing the exact bearing specifications necessary to meet the multifunctional needs of the drone’s actuation systems.
Moreover, Boca’s technical expertise and responsive customer service supported the innovative aerospace team in selecting the most appropriate bearing materials and lubrication options—tailored to withstand the demanding operational environment of the UAV. Collaboration with Boca’s bearing experts and sales engineers allowed the drone manufacturer to optimize grease and oil formulations for precise application requirements.
Implementation
Boca Bearings were integrated throughout the drone’s actuation systems from the earliest stages of the Trio airframe development. This built-in support ensured that every actuation point—critical for maneuvering and system responsiveness—benefited from bearings precisely matched to the aircraft’s design parameters.
Results
Since integration, the aerospace company has observed considerable advancements in drone performance and reliability:
Unmatched Durability: In harsh operational conditions, including crash scenarios, the bearings have maintained structural integrity without damage. This durability significantly enhances aircraft reliability and reduces downtime.
Material and Weight Optimization: Recognizing the paramount importance of weight in aerospace design, the client continues to collaborate with Boca to evaluate alternative bearing materials that might further reduce weight without sacrificing performance or durability—an ongoing process reflecting the partnership’s innovative mindset.
Business Impact
While cost remains an important factor, the Angel Aerial Systems team emphasize that having access to the exact bearing size and material needed is far more critical to their success. The ability to leverage Boca’s comprehensive product range and personalized service translated into smoother design workflows and prevented costly delays associated with sourcing unsuitable components.
When asked about recommending Boca Bearings, the Angel Aerial Systems team was emphatic: “Definitely. Boca has the best selection of bearings we’ve found, and their team is a great technical partner, especially as we push the boundaries of robotics and aerospace systems.”
Conclusion
This collaboration underscores the critical role of partnering with a bearing supplier that understands and supports cutting-edge aerospace applications. Boca Bearings’ extensive and off-the-shelf product range, combined with expert technical insight and responsive service, have enabled the successful development and deployment of the Trio airframe’s advanced actuation systems—delivering durable, reliable, and high-performance UAV operations.
