DJI Enterprise Drone Payload/Gimbal Mounting Bracket

This is the DJI Enterprise Drone Payload/Gimbal Mounting Bracket that we have recently manufactured and processed — it’s a frame expansion accessory for DJI industrial drones (e.g., Matrice series). Its metal bracket structure with mounting holes is designed to secure additional payload devices (such as secondary gimbals, sensors, lighting modules, etc.) to the drone body, ensuring stable connection between the payload and the fuselage through precise positioning. It’s commonly used in professional operation scenarios like surveying and mapping, as well as inspection.

The manufacturing difficulty of this DJI enterprise drone payload/gimbal mounting bracket mainly lies in three aspects: precision control, structural adaptability, and process coordination, which are detailed as follows:

High-precision Assembly Requirements

As a core connecting component for drone payloads, the positional accuracy and aperture tolerance of its mounting holes must be controlled within ±0.02mm. Otherwise, it will directly affect the mounting verticality of gimbals or sensors, leading to deviations in operation data. After the die-cast blank is formed, it has to undergo precision milling, drilling and tapping on multi-axis CNC machine tools, which places extremely high demands on the positioning accuracy of the machine tools and tool wear compensation.

Forming Difficulty of Thin-wall Structure

To meet the lightweight design requirements of drones, this mounting bracket usually adopts a thin-wall aluminum alloy structure . During the die casting process, improper control of aluminum melt flow rate and pressure can easily cause defects such as cold shuts, material shortage and air holes. Meanwhile, the thin-wall structure is prone to deformation during CNC machining, requiring the design of special fixtures for rigid fixation, which further increases the process complexity.

Collaborative Machining of Multi-curved Surfaces and Interfaces

The mounting bracket needs to match the curved contour of the drone fuselage, the flat interface of the payload device, and the rotating positioning groove of the gimbal simultaneously. Complex parting surfaces and core-pulling mechanisms must be planned during mold design. In CNC machining, multiple clamping and position changes are required, which imposes stringent requirements on the versatility of tooling fixtures and the rationality of programming paths.

Balance between Surface Quality and Lightweight Design

Drone accessories have strict requirements for surface roughness (Ra≤1.6μm). Post-treatment processes such as sandblasting and anodization are needed to enhance surface hardness and corrosion resistance. However, anodization will cause minor dimensional deviations. Therefore, precise machining allowances need to be reserved during the manufacturing process to balance surface quality and assembly accuracy.