Lubrication and anti-corrosion solutions inspired by laundry capsules

Aerospace engineers and entrepreneurs Rob and Daniella Sladen wondered why the same lubrication system was used for both 15-minute and 15,000-minute missions. Why did oil systems have to be so complex for engines that were only supposed to run for 30 minutes? The married couple was working on small engines for single-use drones when they came up with the idea of ​​a modular oil tank similar to a laundry detergent tank. The tank automatically activates to distribute fluid in and around the system as it runs.

A new approach to fluid delivery for critical mechanical applications, the ZPod from Zulu Pods combines the function of a reservoir, pump and nozzle into a single, self-contained, self-pressurizing unit. Through patented engineering and design, the ZPod is able to dose the exact amount of fluid for optimal mechanical performance, resulting in a compact, lightweight and modular system.

In May 2024, Zulu Pods successfully integrated and demonstrated the ZPod on an engine test stand, completing a critical milestone in product development. Currently, ZPods are being evaluated for use as primary and backup lubrication systems by the U.S. military. For primary system applications, ZPods replace traditional jet engine lubrication systems that power drones and missiles, providing a significant performance improvement in the form of increased range. In backup lubrication applications, the ZPod provides a self-powered backup oil system independent of the oil pump’s ability to properly circulate oil to critical mechanical components, providing pilots with time to perform evasive landing maneuvers to safely land the rotary-wing aircraft in the event of a loss of lubrication. Later this year, Zulu Pods plans to conduct customer engine testing with several engine manufacturers, paving the way for commercialization of the product, said Tyrone Fitzgerald, Zulu’s marketing manager.

Corrosion protection

Building on Zulu Pod’s patented oil capsule technology, the company will also offer corrosion protection capsules for MROs. The ZPod Corrosion Protection automatically delivers corrosion-preventing fluids at customizable intervals for long-term storage or short-term protection during overhauls. Zulu Pods is developing the technology, Fitzgerald said, and plans to showcase its capabilities at MRO Americas 2025 in Atlanta.

The anti-corrosion module will provide significant labor and cost savings by integrating monitoring of ambient temperature and humidity data, mechanical acoustic frequency and module fluid capacity, he said, as well as analytics such as system failure thresholds and operating trends. The data analysis will provide maintenance managers with valuable insights to prevent system downtime and mechanical failures, he said.