Design Improvement and Finite Element Analysis of a Drone Frame

In response to the growing operational demands placed on Unmanned Aerial Vehicles (UAVs), this research focuses on improving the structural design of micro-drones, such as the DJI Mini 3, which are often hindered by fractured arms and body-frame failures. These failures frequently arise from the use of unsuitable materials and non-optimised frame geometries designed strictly to meet sub-250 g weight regulations. The main goal of this study is to design and analyse a drone frame to achieve an improved strength-to-weight ratio using 3D computer-Aided Design (CAD) software and Finite Element Analysis (FEA). FEA evaluates important parameters, including stress levels, degrees of deformation, and the Factor of Safety (FoS). Moreover, this project involves analysing key material properties to compare and select suitable materials for creating structures that are not only effective but also affordable.