Topology Optimization and 3D Printing of Micro-Drone: Numerical Design with Experimental Testing

The expanding capabilities and decreasing costs of additive manufacturing have resulted in the increased adoption of micro-unmanned aerial vehicles (micro-UAVs) among professionals and hobbyists. Due to safety regulatory requirements of UAV operations, weight is generally the overriding design features of interest for micro-drones, but it often comes as a trade-off against the durability, loading constraints, and other subsystem equipment. Nevertheless, ultra-lightweight structures can be realized through the adoption of both 3D-printing and topology optimization without compromising the structural integrity and overall strength and this article explores the use of these two technologies for designing and manufacturing optimized ultralight micro-UAVs. First, material properties of Nylon 12 (PA12) manufactured using selective laser sintering (SLS) were accurately characterized via mechanical testing and ultrasonic means. These properties were verified by comparing the mechanical response of 3-point and 4-point bending tests with corresponding finite element (FE) simulation. Next, topology optimization was performed to produce an optimized structure of a Z-split configured lightweight micro-quadcopter. The optimized design is then 3D-printed and subsequently validated through a load test for verification against the optimized FE simulation-based design. A close correlation was obtained between the numerical and experimental data, suggesting that topology optimization with 3D printing can be safely and reliably adopted for the design and rapid prototyping of micro-UAVs, whilst catering to different specifications and requirements.