Optimising design and manufacture processes to accelerate delivery

Background

Windracers ULTRA is the world’s most accomplished dual-use heavy-lift drone. With a payload of more than 150kg, and a range up to 2,000 km, ULTRA provides essential support to remote locations and disaster zones that only aircraft can reach. Examples include reconnaissance and resupply in Ukraine, geological and wildlife surveying in Antarctica, parcel delivery off the coasts of Scotland and England, and wildfire response missions.

Challenge

Windracers needed to scale up production, improve processes and meet customer requirements in response to growing customer demand for ULTRA MK1.

Windracers needed to increase manufacturing capacity to keep up with rising demand
Rapid delivery was essential to meet customer expectations and mission timelines
Scaling had to be achieved without compromising design, manufacturing, or supply chain efficiency
Growing global demand required a significant reduction in build and delivery times

Solution

Windracers partnered with PurpleSector to enhance and develop processes for critical delivery functions.

This work spanned design, global supply chain management, manufacturing and project leadership. Strengthening them together, rather than in isolation, allowed Windracers to increase capacity without compromising quality or lead times.

Engineers testing a sustainable marine powertrain system designed for reduced emissions and faster delivery.

A sustainable marine powertrain system designed for reduced emissions and faster delivery.

Results

Windracers ULTRA MK1 build time reduced dramatically, enabling them to meet customer needs on time.

PurpleSector’s assistance was a key step in the development of Windracers manufacturing processes, enabling the company to better meet future demand for ULTRA MK1. Engineered and manufactured in the UK, Windracers ULTRA has operated in Antarctica, Africa, North America, the UK and Ukraine.

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