Topology optimization and 3D printing of a unibody quadcopter airframe

Abstract The performance of any unmanned aerial vehicle largely depends upon its weight as this characteristic dictates its payload capacity and flight duration. This paper presents a multiphysics simulation method for designing a unibody quadcopter airframe with optimum weight in SolidWorks. By adopting the computer-aided topology optimization concept, the mass of the frame is decreased by 91% (from 1558.44 to 134.738 grams) after getting rid of the unwanted elements, while not compromising its structural rigidity. The efficacy of the model is assessed by finite element analysis and it is found that the stress would remain within the acceptable limit. The optimized structure shows an operating life of 1.6×10 5 cycles in the fatigue analysis and experiences significantly less drag force in the computational fluid dynamics test than the original airframe for several angles of attack, thus proving the superiority of the optimized frame over the initial model. Finally, additive manufacturing is performed to fabricate the optimized structure using PLA material. 3D printing through the fused deposition modeling technique is chosen since it is ideal for fabricating intricate engineering prototypes compared to orthodox manufacturing processes. While creating the frame, a 45° overhang angle is maintained to ensure the usage of less support material.