Bio-Inspired Deformable Propeller Concept for Smooth Human-UAV Interaction and Efficient Thrust Generation

This letter presents a novel deformable propeller concept, 3D-printed in flexible thermoplastic polyurethane, which stores impact energy in the form of elastic energy for smooth collisions, reducing risk in human-UAV interactions. However, such a design experiences elastic deformations when exposed to aerodynamic and centrifugal loads. The most relevant occur in the 3-5 krpm range. At higher speeds, the centrifugal force is dominant and the propeller becomes quite stiff. This work provides an investigation of the propeller deformation angles (which ultimately alter the aerodynamic profile and limit thrust generation) based on Fluid-Structure Interaction (FSI) simulations. These results are leveraged to introduce two complementary solutions: deformation reduction oriented internal fiber distributions, inspired by the ultra-efficient dragonfly wings (I); anticipatory designs which pre-modify pitch and roll angles based on simulation results to ensure optimal performance at the target rotational velocity (II). This letter offers a multi-configuration analysis, yielding an easy to manufacture propeller with a specific design methodology which results in increased efficiency and reduced impact recovery time. This work presents collision tests with various objects, as well as a proof of concept for its flight capabilities in a conventional quadrotor, including physical interaction with humans. These findings are valuable for the development of collision control strategies for UAVs.