A Design Modification of a Quadrotor Frame Based on Fused Deposition Modeling

Quadrotor VAVs have mass variations in their performance and cost, or these are made of materials such as carbon fiber, which implies a higher manufacturing cost. Therefore, an alternative is to resort to manufacturing parts using 3D printing to reduce the mass and improve strength of materials. This work focuses on the structural analysis of a quadrotor UAV previously manufactured using 3D printing technology with polylactic acid (PLA) filament as an alternative to higher cost materials. Buckling problems are presented in the original design of the frame, so its design is reinforced by considerably increasing the mass. The main objective is to reduce the mass without compromising the structural integrity. Experimental tensile tests are performed on PLA specimens to determine their mechanical properties, as well as rotor thrust tests to evaluate the maximum loads on the frame. Three frame alternatives are proposed and designed, with the second proposal being the most successful, with a 41% reduction in mass. The structural simulation shows that this proposal complies with the structural limits of the aircraft, highlighting the feasibility of using PLA and optimizing designs using the finite element technique to reduce mass without compromising strength, representing an economical and efficient option in terms of aeronautical engineering.