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Designing new aircraft that are state-of-the-art and beyond always requires the development of new technologies. This paper aims to present lessons learned while designing, building and testing new UAVs in the configuration of the flying wing. The UAV contains a number of aerodynamic devices that are not obvious solutions and use the latest manufacturing technology achievements, such as 3D printing.

The design solutions were applied on an airworthy aircraft and checked during test flights. The process was first conducted on the smaller UAV, and based on the test outcomes, improvements were made and then applied on the larger version of the UAV, where they were verified.

A number of practical findings were identified. For example, the use of 3D printing technology for manufacturing integrated pressure ports, investigation of the adverse yaw effect on the flying wing configuration and the effectiveness of winglet rudders in producing yawing moment.

All designed devices were tested in practice on the flying aircraft. It allowed for improved aircraft performance and handling characteristics. Several of the technologies used improved the speed and quality of aerodynamic device design and manufacturing, which also influences the reliability of the aircraft.

The paper presents how 3D printing technology can be utilized for manufacturing of aerodynamic devices. Specially developed techniques for control surface design, which can affect adverse yaw problem and aircraft handling characteristics, were described.