Advanced optimization of drone frame design through the application of generative design techniques and 3D printing technology

This study explores the integration of generative design and additive manufacturing (AM) to optimize the structural design of unmanned aerial vehicle (UAV) frames. Carbon fiber-reinforced nylon (PA6-CF) was selected as the primary material, utilizing fused deposition modeling (FDM) for prototyping. The research began with the configuration of UAV frame designs, followed by the application of generative design methodologies to generate over 138 design solutions. These were narrowed down to 35 feasible designs based on mechanical performance criteria, with SS-O11 and NO SS-O15 emerging as the top candidates. The selected designs were subjected to finite element analysis (FEA) for static and dynamic simulations. SS-O11 demonstrated minimal displacement (0.12 mm) under a 1400-gram load, a von Mises stress of 3.28 MPa, and a significant weight reduction of 66.28 % from its initial design. Impact tests showed SS-O11 reaching a peak stress of 152.92 MPa, confirming its structural resilience. The study concludes that integrating generative design with AM effectively produces lightweight, strong UAV frames, offering significant contributions to UAV structure optimization.