What type of study is this?

This is a In Vitro Study study.

August 17, 2025Open Access

Drone Frame Optimization via Simulation and 3D Printing

FKFaris KatebKing Abdulaziz University AHAbdul HaseebAbdul Wali Khan University Mardan SMSyed Misbah-Un-NoorUniversity of Engineering and Technology Peshawar

Key Points

The final design minimizes drag and maximizes performance using computational fluid dynamics analysis, leading to a highly efficient drone frame.
Finite element analysis evaluates stress and deformation in the drone frame, which informs material optimization for improved durability.
Topology optimization reduces material while enhancing the stiffness-to-weight ratio, crucial for maintaining flight efficiency.
Fused deposition modeling allows for rapid prototyping of the drone frame, facilitating experimental validation of design improvements.

Abstract

This study presents a simulation-driven methodology for the design and optimization of a lightweight drone frame. Starting with a CAD model developed in SolidWorks, finite element analysis (FEA) and computational fluid dynamics (CFD) which are used to evaluate stress, deformation, fatigue behavior, and aerodynamic performance. Topology optimization is then applied to reduce non-critical material and enhance the stiffness-to-weight ratio. CFD-informed refinements further help to minimize drag and improve airflow uniformity. The final design is fabricated using fused deposition modeling (FDM) with PLA, enabling rapid prototyping and experimental validation. Future work will explore advanced materials to improve fatigue resistance and structural durability.

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