Design of monocoque quadcopter structure through integration of additive manufacturing and topology optimization

Abstract

The concept of topology optimization and additive manufacturing is inculcated for designing the structural frame of a quadcopter. Static structural analysis of the quadcopter design space is carried out using the principles of finite element analysis to understand the deformation and stress distribution. Topology optimization is carried out with mass minimization as an objective and allowable maximum stress as a constraint. Topologically optimized models have complex and uneven shapes which can be built only by additive manufacturing process. Fused deposition modelling (FDM) is suggested for manufacturing the frame as a unified body without the need for assembling structural components of Quadcopter frame. The manufacturing procedure using FDM are discussed based on the principles of design for additive manufacturing. Based on the validation of optimized model through static structural analysis, it is concluded that integration of design methodology with topology 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 innovative shape of minimum weight with complex geometry.