Design, Fabrication, and Installation of Morphing Control Surfaces for Small-Scale UAS

Morphing control surface technology, inspired by organic structures and compliant mechanisms, offers significant potential for enhancing the aerodynamic efficiency and performance of unmanned aerial systems (UAS). Despite these benefits, its adoption has been hindered by complexities in design, manufacturing, and installation, particularly when compared to traditional flap systems. This research explores the design, fabrication, and integration of morphing control surfaces for small-scale UAS using additive manufacturing techniques. To reduce costs and streamline the design process, fused deposition modeling (FDM) additive manufacturing was employed for component fabrication. An off-the-shelf Horizon Sport Cub S2 served as the testing platform, modified with a Speedybee F405 Wing flight controller and a custom modular wing. The modular wing incorporated a novel connection system tailored for the rapid testing and validation of morphing control surfaces, simplifying installation while maintaining flexibility for iterative design improvements. All components were modeled in SOLIDWORKS and fabricated using lightweight, foaming PLA for aerodynamic surfaces, with PETG used for load-bearing components to enhance durability and longevity. The design phase revealed challenges unique to morphing surfaces, which require specialized tools and methods for optimization. Conversely, FDM printing significantly simplified manufacturing, yielding high-quality, reproducible components. However, installation complexities were exacerbated by the increased strain on electrical components caused by flexible 3D-printed structures, potentially impacting their lifespan and reliability. Successful test flights demonstrated that the morphing control surfaces performed comparably to conventional flap systems and are a viable alternative for small-scale UAS applications. Further testing and optimization are necessary to enhance performance, durability, and ease of integration, paving the way for broader adoption of morphing technologies in UAS platforms.