Adaptive Morphing Wing System for Unmanned Aerial Vehicles: Design, Prototype Development, and Experimental Aerodynamic Validation

This technical report presents the design, additive manufacture, and experimental aerodynamic validation of an adaptive morphing wing system for small unmanned aerial vehicles (UAVs). Conventional fixed-geometry wings are constrained to a single optimised flight condition, producing suboptimal aerodynamic performance across the full operational envelope. The proposed system uses a hybrid-material architecture integrating CFRP/ABS structural elements with TPU morphing skin, actuated by SG90 micro servomotors and NiTi SMA wire elements. CFD analysis was conducted in ANSYS Discovery using a k-ω SST turbulence model. The prototype was validated in the AF1300 Subsonic Wind Tunnel at the University of Hertfordshire at 10–20 m/s. Results: 17% lift coefficient increase, 7% drag reduction, peak Cl/Cd = 2.4. Patent: GB2610796.1. Commercial development: AeroFlex Technologies Ltd.