Topographic optimization of 3D-printed drone frames

What is it about?

The current problem with manufacturing a single-frame drone is that there are challenges such as structural integrity as well as material integrity, and that includes reducing the weight of the drone. To design an optimal drone frame, the X and H frame concepts are created using generative design from Fusion 360 and compared to each other to make the right choice. The first designs are taken into account in generative design with load cases at each motor point, so that the result of the drone has optimal structures that are both light and robust. In combination with 3D printing, it is possible to produce the complex geometries and reduce material waste. Through the simulations of the drone and the analysis of the data, the decision finally fell on the H-frame made of PLA+. This includes factors such as weight, Von Mises stress, and displacement.

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Photo by david henrichs on Unsplash

Photo by david henrichs on Unsplash

Why is it important?

A direct comparison between the X-frame and H-frame shows that the design and their possible applications differ. By analysing the two frames, it becomes clear that the design is different and the loads are distributed very differently on the arm of the drone. This is initially noticeable through the choice of material, as the H-frame outputs values from the analysis and the properties of the design that are clearly in favour of PLA+. For the X-frame, the choice of material can be a little more complicated. The choice can also be made between ABS, PLA and PLA+, but the decision between the three materials should have further requirements, such as cost, recyclability and biodegradability.

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