Design and Testing of Recycled 3D Printed Foldable Unmanned Aerial Vehicle for Remote Sensing

Substantial progress in battery and control technology has drastically enabled unmanned aerial vehicles (UAVs) to evolve and develop for utilization across a broader array of applications. Remote sensing imagery in UAVs are evidently exhibiting its remarkable reliability, efficiency and integrability. Furthermore, technological advancements in additive manufacturing enable rapid prototyping of designs in a more cost-effective manner. This paper describes the design, construction and testing of a UAV with a foldable airframe, manufactured from recycled Polyethylene Terephthalate (PET) plastic, through 3D printing filament for the purpose of remote sensing. Previous contributions demonstrated the ability of manufacturing UAVs from recycled plastic and the feasibility of utilizing PET. This paper further develops the design, functionality and application of the UAV through additional material testing, design optimization and added design features. The new UAV design features include; propeller protection to enable remote sensing in isolated and inaccessible areas, integrated printed circuit board (PCB) to power onboard systems and reduce cable clutter, and material testing and analysis for usability of PET in multiple extreme weather environments. Moreover, the optimized UAV design will allow ease of integration with onboard systems, as well as cater for multiple interchangeable rotor arm designs, including protected and unprotected propeller designs. The objective of the research and investigation is focused on the development and implementation of cost-effective and environmentally sustainable UAVs. This paper strives to enable UAV manufacturers to rapidly prototype and optimize UAV designs, while simultaneously deterring PET plastic pollution globally, with negligible effect on UAV functionality.