Redesigning UAV Vertical Tail Structures with Lightweight Eco-Friendly Carbon-Reinforced Polymers: A Generative Design-Based Approach

The increasing adoption of additive manufacturing in applications requiring high strength, stiffness, and lightness has highlighted the need to outclass the classical design methodologies. As a matter of fact, traditional design approaches often fail to exploit additive manufacturing’s full potential. To address this need, this research presents an innovative design of a vertical tail for an unmanned aerial vehicle by integrating the generative design optimization strategy for additive manufacturing and engineered technopolymers reinforced with chopped carbon fiber. The proposed iterative method, combined with a high strength carbon fiber material, led to significant mass reductions, up to 71.2%, compared with a metallic design.