Path Optimization From En Route 3d Printed Aircraft Using Physics-Based Estimation Methods and Surrogate Models

Abstract In a previous study, a general approach to increasing the range capability of an unmanned aerial system was assessed by 3D printing components or parts for the UAS while a carrier platform, of both the printer and UAS systems, travels to a launch point for the UAS. As a result, the platform could launch the UAS from a distance further away from the location of interest. This paper outlines the parameters of a physics-based model to determine the actual range increase of an attritable aircraft, constrained by the amount of time available for printing while en route. It develops the formulation of the UAS range increase from the lift-to-drag ratio increases caused by the physical wing section enhancements printed in a constrained amount of time while the carrier platform travels from one location to another. The relationship is leveraged to optimize the shortest path necessary for the carrier platform to access or reach the set of locations of interest in an operational environment. Scenarios of up to 15 locations are explored by first optimizing the sequence of the locations in a traveling salesman problem and then optimizing the actual path taken by the carrier platform along that sequence. Statistical results are presented to summarize the benefits of 3D printing en route across different scenarios.