Optimization Design and <scp>3D</scp> Printing of a Continuous Carbon Fiber‐Reinforced Unmanned Aerial Vehicle Shell

ABSTRACT Unmanned aerial vehicles (UAVs) necessitate structural components that are lightweight yet mechanically robust to enhance flight performance and energy efficiency. This study investigates the application of continuous carbon fiber‐reinforced composites (CCFRC) in the 3D printing of UAV shell structures. A self‐developed continuous carbon fiber/nylon prepreg filament was prepared using a melt impregnation technique, achieving a fiber volume fraction of 54%. Furthermore, a quasi‐isotropic [0/45/–45/90] fiber layup configuration was meticulously designed to optimize mechanical properties. Tensile specimens fabricated from the modified filament exhibited a tensile strength of 316 MPa. At the same time, finite element analysis and mechanical testing demonstrated that the UAV shell could sustain an effective load of 600 N and achieve a 25% reduction in structural weight. These findings underscore the potential of combining continuous fiber prepreg technology, additive manufacturing, and structural optimization to enhance UAV performance in terms of materials, manufacturing processes, and structure. This approach provides a scalable pathway for the industrial application of aerospace‐grade composite structures, paving the way for advancements in UAV performance and design flexibility.