Optimal methodology for designing and testing multicopter arm made of composite materials

The modern unmanned aerial vehicle (UAV) industry relies heavily on structures made of composite materials. This study focuses on designing the structure of a military-grade multicopter. This type of UAV must meet rigorous standards to prevent risks of damage or even catastrophic failure during missions. One of the most challenging parts for design is the multicopter arm since it is exposed to high-magnitude forces during flight. Understanding these forces and how to withstand them is of crucial importance for good arm design. In this research, where the goal was to define the optimal methodology of arm design, it was necessary to conduct a static propulsion test to determine maximum force acting on the arm. Then, the arm design was validated using the finite element method (FEM) in combination with static experiments held on a specially created test stand. Finally, the production process, as one of the most demanding aspects of designing the arm, was carefully planned and defined, as it required not only selecting the appropriate materials but also mastering the technologies for high-quality arm manufacture.