Design and Development of Quadcopter Frame Through Topology Optimization

Unmanned Aerial Systems (UASs) are gradually gaining popularity in agricultural and defense sectors. Quadcopters are the most common type of UASs due to their inherent advantages, such as mobility, ease, and control. Travelling for a longer period by properly loading may be challenging. The quadcopter's battery depends on its weight in terms of its duration and efficiency. The frame is the structural part of UAS that carries the complete load of the equipment. It is recommended that the UAS frame be optimized because it contributes significantly to the total weight of the UAS, which is about 30 per cent. Current business UAS models consist of many subassemblies and additional hardware fastening points that require substantial time and effort to join. In this research, the frame is transformed into a monocoque structure, which gave good results in terms of weight optimization and time taken for assembly. Topology optimization can thus be used to construct lightweight structures without compromising the structural performance. The design for the quadcopter frame was modeled, and topological optimization was doneto arriveg at the best structure. Topology optimization provided an intricate shape for the model, which was challenging to manufacture through conventional methods; therefore, the optimized model was re-modeled and checked through the statically structural Finite Element Analysis (FEA). The optimized design is then produced through the 3D printing technique. The Powder Bed Fusion (PBF) process is used to create the redesigned quadcopter structure; the field trials indicate that the quadcopter we developed offers users a variety of benefits, including high endurance, greater maneuverability, and a significantly shorter deployment time. Consequently, it is a suitable drone for rapid response in surveillance applications.