Design, optimization and manufacturing of quad copter frame using FDM

Abstract

This paper explores two important aspects of quadcopter design viz., design optimization using Non-dominated Sorted Genetic Algorithm (NSGA) technique and fabrication of monocoque quadcopter frame. Arm width, arm thickness, thickness of the ring connecting the four arms and dome thickness are the parameters considered for the design of experiments (DoEs). Once the optimized set of parameters is achieved, transient simulation is carried out to test the performance of the quadcopter frame. Mass and thrust-to-weight ratio of the optimized quadcopter frame are compared with that of a commercially available quadcopter frame of the same size. It is observed that there is a significant increase in the thrust-to-weight ratio and a decrease in the mass of the frame. Sensitivity analysis of the DoE results shows that the dome and ring thicknesses have higher influence on the optimized model. Based on the validation of optimized model through static structural analysis, it is concluded that integration of design optimization and additive manufacturing will reduce the usage of material which results in a more budget friendly design. The result of this approach gives a structural frame of new design with monocoque structure of minimum weight with higher performance.