Design and Simulation of Micro-UAV using Topology Optimization and Additive Manufacturing Technology

The expansion of capabilities and the continuous development of additive manufacturing technology have led to a reduction in costs for custom product manufacturing and have enabled the production of complex structures for micro-drones. Weight is generally one of the primary design features of micro-drones, often considered a trade-off against durability and other functionalities. However, ultra-lightweight structures can be achieved through additive manufacturing and topology optimization without compromising structural integrity. This study examines the use of these two technologies for designing and fabricating optimized lightweight micro-drones. Generative design using artificial intelligence algorithms performs topology optimization for optimal load distribution, demonstrating its efficiency in various simulations. This research addresses the complexities of micro-drone design and the interdependence between geometry, manufacturing methods, and materials. In this study, a square-frame micro-drone was constructed using Fused Deposition Modeling (FDM) with PETG filament. The selected material's properties were determined through mechanical testing and literature review. Subsequently, topology optimization was conducted to create a lightweight body structure with an X configuration. The optimized design was 3D printed and validated through load testing to verify finite element simulation results. The experimental and simulation results indicated that the combination of topology optimization and 3D printing can be safely and reliably used for the rapid design and production of micro-drones. The final optimized model produced through additive manufacturing could withstand a load 100 times its own weight, demonstrating superior performance compared to previous designs.