Just noticed what appears to look like a stress crack on the left side, just above the screw though I'm not sure, it really is thin and barely noticeable. I never had a crash and I'm always extra careful not to aply force on the arms. Has anyone else noticed something similar? Guess I'll be monitoring it closely from now on to see if it becomes more prominent.

It's a bit hard to tell for sure, from the pictures - it looks like a surface scratch.  Does applying light pressure to the area cause any separation or deformation?

Blériot53 Posted at 3-25 08:21
It's a bit hard to tell for sure, from the pictures - it looks like a surface scratch.  Does applying light pressure to the area cause any separation or deformation?

No, it doesn't separate but it's also not a surface scratch, more like as if a deeper layer of the plastic would be cracked and only visible through the surface.

Hrodnand Posted at 3-25 08:33
No, it doesn't separate but it's also not a surface scratch, more like as if a deeper layer of the plastic would be cracked and only visible through the surface.

Unless it spreads to an edge, maybe you have nothing to worry about.  It certainly merits keeping a close eye on though.

Hello there Hrodnand. Thank you for reaching out and for giving out these information. If you feel that if issue is affecting your DJI Air 2S and is not working or performing properly. I would recommend you to contact our DJI support team at https://www.dji.com/support?site=brandsite&from=nav for further assistance and just a reminder that it is not recommended to fly your DJI drone if these are stress crack on it. This cracks might affect the performance of the said drone while on flight and may lead to an unwanted incident. Thank you.

If the drone is U/W I would suggest open a case with Dji support, you don't want when the warranty expires then it cracks and you are left with that drone.

I'm coming with an update here. I've kept monitoring the crack after the past couple flights and unfortunately yesterday I noticed that the material eventually cracked entirely, now displaying a complete fissure. As I mentioned earlier I never had a crash, nor stressed the aircraft in the slightest bit, avoided sub 0 C temperatures and Sport mode not to stress the material in any way, and always handled it with extra care.
It saddens me because I really hoped this wouldn't happen, I noticed that frequent stress cracks appeared on the Mavic Air 2 with other users, while the frame of the Air 2S seemed to be sturdier. Other than this, I was completely satisfied with the aircraft and never had any other problem. I've issued a replacement procedure at DJI and now waiting for a reply.

I forgot to mention, if anyone noticed something similar, please share your experience. I'm curious to know how frequently these cracks occur?

Hrodnand Posted at 5-1 21:44
I'm coming with an update here. I've kept monitoring the crack in the past couple flights and unfortunately yesterday I noticed that the material eventually cracked entirely, now displaying a complete fissure. As I mentioned earlier I never had a crash, nor stressed the aircraft in the slightest bit, avoided sub 0 C temperatures and Sport mode not to stress the material in any way, and always handled it with extra care.
It saddens me because I really hoped this wouldn't happen, I noticed that frequent stress cracks appeared on the Mavic Air 2 with other users, while the frame of the Air 2S seemed to be sturdier. Other than this, I was completely satisfied with the aircraft and never had any other problem. I've issued a replacement procedure at DJI and now waiting for a reply.

This looks like a production defect. You should open a ticket with dji and have it replaced if under warranty. I take care of my Air 2S like my baby and haven't noticed anything of this sort yet but if this is the case, it is horrible to say at least. The plastics should have been more sturdy than regular no-name brand drones.

dreamtuner Posted at 5-2 00:49
This looks like a production defect. You should open a ticket with dji and have it replaced if under warranty. I take care of my Air 2S like my baby and haven't noticed anything of this sort yet but if this is the case, it is horrible to say at least. The plastics should have been more sturdy than regular no-name brand drones.

Indeed, that's what I thought as well. I read somewhere that if the screws are placed in too tight, there can be small cracks with time in the material as the vibrations spread through it. Every small crack can worsen as it has to continiously withstand the vibrations of the aircraft.

I think it has grown in length too, in both directions. If so I'd be asking for a repair or replacement if it is still under warranty.

Sean-bumble-bee Posted at 5-2 01:11
I think it has grown in length too, in both directions. If so I'd be asking for a repair or replacement if it is still under warranty.

Yes, I have Care Refresh available and applied for a replacement.

Hrodnand Posted at 5-2 01:18
Yes, I have Care Refresh available and applied for a replacement.

IT IS NOT a care refresh issue. Providing the drone is within the warranty period it is a warranty issue, you should NOT be paying for it!!!!!!

Sean-bumble-bee Posted at 5-2 01:46
IT IS NOT a care refresh issue. Providing the drone is within the warranty period it is a warranty issue, you should NOT be paying for it!!!!!!

You're right. I'm an idiot, just spoke with DJI, cancelled my case and requested for a refund which they said is OK for them. I'll contact the seller directly and request a replacement since I still have warranty. Thanks a lot for giving me a heads-up!

Uuum can DJI themselves not process it as a warranty issue rather than involving the seller? I am just thinking it might be simpler and quicker to go straight to DJI.

Sean-bumble-bee Posted at 5-2 02:36
Uuum can DJI themselves not process it as a warranty issue rather than involving the seller? I am just thinking it might be simpler and quicker to go straight to DJI.

Yes, that's just what I did. I realized it might be a better idea. Thanks a lot for helping!

DIdn't initially look like a stress crack.  It looked like a single hair bristle off a cleaning brush, which got painted over at factory.   Good eye for catching crack early on.

HedgeTrimmer Posted at 5-2 05:42
DIdn't initially look like a stress crack.  It looked like a single hair bristle off a cleaning brush, which got painted over at factory.   Good eye for catching crack early on.

I wasn't sure myself that it's a crack until the plastic got separated and the fissure appeared. Maybe it wouldn't have any effect or the crack wouldn't spread/worsen but better be safe with an intact frame since it's still an aircraft. My bet is on that screw below which was tightened too much, thus provoking the plastic to crack during flight.

Another update here. I sent the drone back for warranty repair to DJI Support and they told me they would change the middle frame module free of charge as part of warranty repair. Hope the new frame will last.
Thanks, DJI!

Hey, I found similar crack, next to memory card slot. Never crashed the drone, no hard landings. I had it from brand new.

Tomasz Laptas Posted at 4-6 08:16
Hey, I found similar crack, next to memory card slot. Never crashed the drone, no hard landings. I had it from brand new.

If it has warranty, contact DJI Support!

https://support.dji.com

Tomasz Laptas Posted at 4-6 08:16
Hey, I found similar crack, next to memory card slot. Never crashed the drone, no hard landings. I had it from brand new.

I'm curious, is your aircraft roughly the same age as this thread? The only reason I ask is that I've rarely seen this crack show up. Usually they appear around/near the arms.

Tomasz Laptas Posted at 4-6 08:16
Hey, I found similar crack, next to memory card slot. Never crashed the drone, no hard landings. I had it from brand new.

I had mine replaced with warranty, the new one was fine and no crack appeared afterwards. Apparently some of them simply crack due to vibration stress during flight. I remember seeing similar "stress cracks" on some Mavic Air 2 models but also on some of the Mavic 3. It's important to make a thorough inspection, regardless of the aircraft model, after each flight so that you notice these cracks in case they appear.