360-Degree Drone Testing Excellence - Part 1 - From Lab Data to Launch Deployment

As Unmanned Aircraft Systems (UAS) and Advanced Aerial Mobility (AAM) influence the National Airspace System (r)evolution; the need for robust safety data, reliability, and efficiency is more pressing than ever.

Autonomous drones will soon be buzzing around our cities, delivering packages with precision, while public safety and combat UAVs will operate flawlessly in the most challenging environments, protecting lives and maintaining global security.

In this article, I address the (flying) "elephant in the (virtual) room" , with a simple question: How do we ensure these cutting-edge technologies are not only innovative but also safe, reliable, and ready for the skies?

The (Flying) "Elephant in the Room" - The Problem

Testing a commercial drone today is daunting, expensive, and inefficient. Each new drone design experiences about 5,000 test flights and between 300 to 500 flight hours to validate technical improvements. But the reality is, the existing testing options are severely lacking.

• Outdoor testing, the most common method, is unreliable, non-repeatable, and uncontrollable, leading to poor-quality data that barely scratches the surface of what’s needed for true validation.
• Wind tunnels, while useful in certain contexts, fall short for drones. They don’t allow free-flight testing and fail to replicate real-world weather conditions, all while driving up costs.
• And then there are the truly rudimentary methods, like using common leaf blowers to simulate wind conditions; an approach that’s not only scientifically inadequate but also highlights a troubling lack of maturity in the industry.

These methods are simply not up to the task of ensuring that the drones we’re sending into the skies are as safe and reliable as they need to be.

360-Degree Testing Excellence - The Solution to the Problem

Whether you're an engineer designing cutting-edge drones, a program manager balancing the demands of innovation and deadlines, a founder pushing the boundaries of aerial mobility, a CEO driving your company toward new heights, or a regulatory gatekeeper tasked with ensuring safety in the skies, your role in the answer to this question is vital.

"No matter your position, making sure these aircraft are thoroughly tested, validated, and ready for the National Airspace System (NAS) is not just important, it’s essential. The key to unlocking the desired outcomes with a cost effective efficient process, is in leveraging a single, comprehensive facility that integrates Failure Modes and Effects Analysis (FMEA), Operational Risk Management (ORM), and state-of-the-art Testing, Inspection, Validation, and Certification (TIVAC) processes, all underpinned by a solid Safety Risk Management (SRM) framework."

The 360-degree solution to these challenges is one that merges cutting-edge technology with a commitment to safety and efficiency. It starts with the FMEA, followed by ORM, and TIVAC that becomes the building blocks of a robust Safety Management System (SMS) that will transform how we develop and deploy UAS and AAM systems.

FMEA (Failure Modes and Effects Analysis) is our first line of defense—a powerful tool that allows us to foresee potential failure points long before they become critical issues. By identifying and addressing these risks early in the development process, we’re not just building safer systems; we’re ensuring that these systems are reliable, efficient, and ready to meet the demands of the airspace (r)evolution.

But it’s not enough to simply anticipate risks; we must manage them in real-time. That’s where: ORM (Operational Risk Management) comes in. For commercial applications, ORM ensures that drones and aerial systems operate safely under everyday conditions, with continuous monitoring and real-time adjustments. However, in the high-stakes world of combat missions, ORM takes on an even more critical role. Here, it’s about precision, speed, and reliability in the face of the unknown. These systems must make mission-critical decisions, respond to threats in an instant, and adapt to ever-changing environments because when lives are on the line, there’s no room for error.

Together, FMEA, ORM, and TIVAC provide a comprehensive framework that blends innovation with safety, efficiency, reliability, and foresight concurrant with real-time adaptability. It’s about creating a future where unmanned systems don’t just meet expectations—they redefine them.

360-Degree Testing Excellence - The Role of Safety Risk Management (SRM)

According to FAA Order 8040.6A,, SRM is an integral part of the Safety Management System (SMS) and is designed to provide comprehensive information regarding hazards, safety risks, and risk controls to enhance decision-making. The SRM process ensures that all hazards are systematically identified, assessed, and mitigated, enabling a more consistent, coordinated, and timely approach to managing safety risks in the NAS. The integration of SRM with FMEA and ORM within a TIVAC framework allows for a holistic approach to risk management; particularly for UAS operations, where the environment and operational complexities are continuously evolving.

360-Degree Testing Excellence - The Blueprint

The WindShape TIVAC facility in Tulsa Oklahoma, offers a unique testing and validation environment where FMEA, ORM, and TIVAC processes converge to provide a comprehensive fusion of testing and validation for UAS and AAM systems. This unique facility is designed for manufacturers, operators and regulators to simulate and capture data from a wide range of environmental conditions; enabling systems to be tested under realistic scenarios that can replicate both commercial and combat mission use-cases within a laboratory setting.

360-Degree Testing Excellence - The Impact

• Engineers can focus on innovation, confident that their designs will undergo rigorous testing under controlled conditions
• Program Managers can streamline processes, ensuring their projects stay on schedule and within budget
• Founders and CEOs gain a competitive edge by bringing products to market that meet the highest safety and performance standards with performance that can be validated, versus the competition
• Regulators can trust that systems have been exhaustively tested, ensuring compliance with all necessary safety regulations

360-Degree Testing Excellence - The Proving Ground

For the combat and public safety use cases, the WindShape Tulsa Oklahoma facility offers a significant strategic advantage. As combat and public safety operations increasingly rely on unmanned systems and artificial intelligence (AI), the need for a repeatable testing environment where AI can learn and adapt is critical.

WindShape's facility provides a 'sandbox', allowing AI and autonomous systems to be tested and refined under a variety of controlled conditions that replicate actual environments.

360-Degree Testing Excellence - Desired Outcomes

Ensuring reliability means tackling potential failure points head-on, long before they have a chance to derail the mission. By identifying and mitigating these risks early in the development process, we're not just validating the systems; we’re validating autonomous systems that you can bet your life on, especially in mission-critical scenarios. But this testing ecosystem doesn't stop there.

We'll make recommendations for enhanced efficiency by pushing these systems through the most diverse and demanding operational environments, optimizing them for peak performance, whether they’re navigating the complexities of urban landscapes or the unpredictability of a battlefield. We'll also capture the data to realize their accuracy, so nothing is left to chance. By rigorously testing AI in a controlled, repeatable environment, we capture the data to fine-tune its decision-making capabilities , validating that when it matters most, the system will perform flawlessly, minimize disruptions and mitigate the risk of errors.

360-Degree Testing Excellence - 'One-to-Many' and Artificial Intelligence (AI)

"In both military and commercial applications, AI is the driving force behind the advanced capabilities of UAS and AAM systems, from autonomous navigation to real-time decision-making. A repeatable testing environment is crucial for AI to learn, adapt, and evolve, particularly in 'one-to-many' scenarios where a single operator or system manages multiple drones simultaneously."

In the drone industry, 'one-to-many' refers to situations where one operator controls or one system manages several drones at once. This approach is key in both military and commercial operations, where efficiency, coordination, and rapid decision-making are paramount.

Here's some examples:

• Combat Use Case - In combat scenarios, a single operator might manage multiple drones for missions such as surveillance, reconnaissance, or offensive operations. AI-driven systems allow these drones to operate autonomously, making real-time decisions even in the most complex and dynamic environments. For instance, AI algorithms must navigate contested airspace, identify and track targets, and execute coordinated strikes. The ability to test and refine these AI systems in a repeatable environment ensures they perform reliably, handling the unpredictability of combat with minimal human oversight.
• Commercial Use Case - In logistics, a single system might control a fleet of delivery drones, coordinating routes, managing battery life, and optimizing delivery schedules. AI is crucial here, enabling drones to autonomously avoid obstacles, adjust to changing weather conditions, and make real-time decisions to ensure timely deliveries. Testing AI in a repeatable environment allows developers to fine-tune these algorithms, ensuring they can handle the complex demands of commercial operations.

360-Degree Testing Excellence - AI and Beyond

Beyond one-to-many applications, AI in drones also enhances autonomous navigation and control by processing data from multiple sensors (like cameras, LiDAR, and GPS) to make real-time decisions.

In the commercial sector, this is vital for applications such as delivery services, agricultural monitoring, and infrastructure inspection.

In combat settings, it enables drones to autonomously conduct reconnaissance, surveillance, and even strike missions in contested environments.

AI also plays a critical role in sensor fusion and data analysis, where it integrates data from various sensors to provide accurate, actionable insights. For example, commercial drones might use AI to analyze multispectral images for crop health, while military drones rely on AI to detect, identify, and track targets with high precision.

Predictive maintenance is another area where AI is indispensable. In commercial applications, AI predicts when drone components might fail, allowing for timely maintenance and minimizing downtime. For military drones, AI-driven predictive maintenance is crucial for preventing mission-critical failures under harsh conditions.

Simulation and virtual testing environments are used extensively in both sectors, where AI-driven simulations help developers understand how drones will perform under various scenarios, from urban landscapes to combat conditions.

Finally, AI-enhanced decision-making and swarm intelligence are tested rigorously to ensure that drones can operate effectively in both commercial and combat contexts. Whether optimizing routes for delivery drones or coordinating autonomous swarms for military operations, AI ensures that these systems operate with greater reliability, efficiency, and accuracy.

Capturing data in a repeatable testing and validation environment is essential for developing AI and mitigating disruptions. This allows for the continuous refinement of AI algorithms, ensuring that drones can operate safely and effectively in the real world, delivering packages in busy cities or executing complex missions in hostile environments in-compliance, with public trust across the board

360-Degree Testing Excellence - a Comprehensive TIVAC Approach

"The integration of FMEA, ORM, SRM, and comprehensive TIVAC testing within the WindShape TIVAC facility not only enhances the safety and reliability of UAS and AAM systems but also ensures compliance with regulatory standards. This comprehensive approach in a single location allows for the capture of the critical data that is needed for systems to be validated while lowering the development cost and accelerating the development path to deployment."

TIVAC services bring together FMEA and ORM under a unified framework, ensuring that the data from every aspect of a UAS or AAM system is tested, inspected, validated and captured before deployment. This comprehensive approach is critical for meeting the stringent requirements of the FAA and other regulatory agencies. It also provides a clear path from development to deployment, reducing the risk of costly delays and ensuring that systems are ready for the demands of real-world operations.

"The Safety and Validation 360 Degree 'Blueprint to Excellence' at the WindShape facility in Tulsa Oklahoma represents a unique convergence of innovation, technology and expertise in the TIVAC ecosystem "

What sets WindShape apart is its unrivaled ability to simulate the vast spectrum of environmental conditions that UAS and AAM cutting-edge technologies will face in the real world. Within its state-of-the-art laboratories, WindShape creates a controlled yet highly realistic testing environment, where innovation meets reality. With proprietary technologies like WindShaper, WindVision, and WindProbe, we’re not just testing the limits; we’re redefining them. These advanced tools enable our 360 Degrees Excellence Philosophy to push the boundaries of what’s possible, ensuring that every system we develop is not only visionary in design but also robust and reliable in the most challenging conditions.

Here's are some of the unique laboratories that WindShape offers in this single location:

• Propulsion Lab - The Propulsion Lab is dedicated to testing UAV propulsion systems under various scenarios to ensure reliable performance across all conditions. Whether it’s the intense stress of military operations or the demands of commercial logistics, the lab provides essential data on how propulsion systems perform under different loads, speeds, and environmental factors. This ensures that both military and civilian UAVs can operate efficiently and effectively, regardless of the challenges they face.
• Climate Labs - WindShape’s Climate Labs simulate extreme temperatures and humidity levels, allowing UAVs to be tested for resilience in harsh environments. For combat drones, this means ensuring reliability in desert heat, arctic cold, or tropical humidity. For commercial UAVs, it means reliable performance in the diverse climates they will encounter in everyday operations.
• Wet Labs - The Wet Labs at WindShape are designed to evaluate the impact of moisture and rain on UAV systems. In combat applications, where UAVs may need to operate in rain, fog, or over bodies of water, this testing is critical to ensure mission success. In civilian use, the ability to operate in adverse weather conditions expands the operational window of delivery drones, search and rescue UAVs, and other commercial systems.
• EMC Labs - Electromagnetic compatibility is crucial for any UAV system, as it prevents interference that could disrupt operations. WindShape’s EMC Labs test for this compatibility, ensuring that UAVs can operate securely in environments filled with other electronic devices and signals. This is especially critical for combat UAVs, which must maintain secure communications in electronically contested environments, and for commercial UAVs that must coexist with the myriad signals found in urban areas.
• Flight Activity Areas 1 & 2 - These areas provide controlled environments for comprehensive flight testing, focusing on critical phases such as takeoff, hover, and landing. The ability to conduct these tests indoors under controlled conditions allows for precise data collection and repeatable testing scenarios. For combat UAVs, this ensures readiness for complex missions. For commercial drones, it validates performance during critical operational phases, ensuring reliability and safety in daily use.
• Sub Systems Labs - WindShape’s Sub Systems Labs are dedicated to testing the integration and performance of sensors, cameras, and communication systems within UAVs. This is particularly important for combat UAVs, where the integration of multiple subsystems must function flawlessly in the field. In commercial applications, ensuring that all subsystems work together seamlessly can mean the difference between a successful delivery and a failed mission.
• GNSS Technology Lab - In the GNSS Technology Lab, WindShape simulates realistic navigation scenarios, providing accurate testing for systems that rely on GNSS data. This lab is crucial for testing the navigation systems of both military and commercial UAVs, ensuring that they can operate accurately and efficiently, even in GPS-denied environments or areas with poor signal quality.
• Skyway36 Droneport and Skyway Range - WindShape’s facility is located at the Skyway36 Droneport and the expansive Skyway Range; a 1,200-square-mile UAS flight test area with "beyond visual line of sight" capabilities. This allows for a seamless transition from controlled indoor repeatable testing in the WindShape Facility - to real-world outdoor testing in diverse rural and urban environments. The integration of indoor and outdoor testing capabilities provides an unparalleled opportunity to validate and certify UAV systems comprehensively before they are deployed.

360-Degree Testing Excellence - Where Innovation meets Validation

The integration of FMEA, ORM, SRM and comprehensive TIVAC testing services within WindShape’s facility enhances the safety, reliability, accuracy and efficiency of UAS and AAM systems. This holistic approach is essential for advancing the development of these systems, reducing time to market, and ensuring they are ready for the complex demands of modern operations.

Part 2 - 360-Degree Drone Testing Excellence - The Validation Blueprint

As we’ve navigated the complex discussion of UAS and AAM testing in this first part, it’s clear that we’re on the leading edge of a transformative era in aerial mobility.

But this is just the beginning. If you'd like to learn more about what’s possible and committed to ensuring that innovation never comes at the cost of safety or reliability, then I'm inviting you to click over to Part 2 of this series: "The Validation Blueprint." In Part 2 we'll discuss the framework for validation; a game-changer that might just help to redefine our thinking into a holistic approach that will help us advance the development of these systems, to realize a reduction in the time to market, and a validation process that's ready for the complex demands of modern operations. . Read Part 2 where technology meets rigor, and where vision meets execution.

Click here to learn more in Part 2 entitled : "360-Degree Drone Testing Excellence - The Validation Blueprint"