Manufacturing Matters- Tuesday Top-Up 68

From the University of Canterbury

The school of Mechanical Engineering is on the hunt for Final Year Project topics!

Mechanical Engineering Final Year Projects bring together design, modelling, analysis, and validation to explore complex engineering problems with real unknowns, rather than routine solutions. Each year, multiple student teams work in parallel on industry- and research-informed challenges, taking projects through to a proof-of-principle or working prototype stage and presenting their outcomes as part of a structured programme.
Strong projects offer sufficient scope for a small student team to take ownership of different work streams and involve an engaged sponsor who can provide regular guidance and an external perspective.

With the new term commencing shortly, we invite organisations interested in collaborating with our students to propose project topics.

A Fireside from 2025 with speaker Alexander Brem
(All images are courtesy of newzealandenergy@substack.com )
Drones depicted a horse rearing over the city to celebrate the New Year in Busan, South Korea.

These shows are as technically challenging as they are spectacular visually. To start with, drone movements must be highly synchronised; every drone in the swarm (often 500 to 3000+ units) must operate on a perfectly synchronised clock. A delay of even a few milliseconds can ruin formations and animations. This requires highly precise GNSS (GPS/GLONASS/Galileo) timing and precision positioning. Standard GPS (accurate to ~5–10 meters) is insufficient for drone shows where units fly within 1.5–3 meters of each other. Operators use Real-Time Kinematic (RTK) GPS, which utilises a ground-based base station to correct satellite signals, achieving centimetre-level accuracy.

Flight formation algorithms use software like Blender with specialised plugins to convert 3D art into flight paths. For fireworks-like effects, the software must simulate “particle physics”—for example, calculating how “trails” of light should follow a moving drone to mimic the look of a rising rocket or a falling spark.

At the same time, the system needs some level of de-centralised logic. If one drone drifts, its neighbours should adjust slightly to maintain the overall shape without requiring central intervention. Moreover, drones are highly susceptible to wind. Wind speeds exceeding 25 – 35 km/h can make it impossible for the drones to maintain their precise formation, leading to a “ghosting” effect where the image becomes blurry.

The next challenge is communication. A robust, low-latency radio link must send real-time commands to every drone. For large swarms, this is often achieved using a mesh network – where drones relay signals – to counteract the risk of drones in the middle of the pack having their signals “shaded” by the bodies of the drones on the perimeter of the swarm.

And then there are, of course, the actual ‘fireworks’. While some drone light shows still rely on pyrotechnics, which comes with a set of its own challenges, increasingly LED lights are used to achieve the desired visual effects without the noise and air pollution created by pyrotechnics. With LEDs, the audience’s view depends on the brightness and colour of the LED lights. Achieving a vivid, firework-like brilliance that’s visible from kilometres away, especially against light-polluted urban skies, requires high-power, efficient LEDs and careful angling.

In summary, the core challenge with drone light shows is transforming a swarm of individual, fragile, GPS-dependent robots into a single, robust, fault-tolerant display system that performs with military-grade precision in unpredictable public environments. It requires a combination of aerospace engineering, robotics, computer science, and meticulous operational planning.

“Military-grade precision” being the key operative term here. The use of swarms of unmanned drones in military operations is rapidly becoming a core element of military strategy, and one may safely assume that there is ample cross-fertilisation between these drone light shows and their military equivalent.

•In psychology, the term ‘Regression’ describes “an unconscious defence mechanism where an individual reverts to behaviours, thoughts, or emotions from an earlier developmental stage to cope with stress, trauma, or anxiety.”

•In automotive technology, there are two recent examples of deliberate technological regression, caused by safety concerns in both cases. We’ll introduce the first one this week. In dashboard design, the knobs are back:

Dashboard of a Jaguar Mk X (420G) – 1961 to 1970

What caused these guideline updates was growing evidence of the risks associated with the expanding use of menu-based touchscreens to control an increasing number of operational functions in modern cars. For example:

The story above is a good example of the age-old design dilemma of Form vs. Functionality. Where industrial designers have complete freedom to operate, they can find the right design that balances visual and haptic attractiveness with utility, but in the case of car user interfaces in the widest sense, at least for the Chinese market what the customer wants isn’t objectively what’s best for them.

Fun facts

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