Quadcopters represent rotary wing configuration of the Unmanned Aerial Vehicles (UAVs) with immense application potential in industrial and strategic contexts. Tradeoff between flight endurance and payload capacity renders design optimization of UAVs a critical activity with substantial impact on the application possibilities. Among the structural parts of a typical Quadcopter, the central body frame constitutes major portion of the total weight. The present study aims at reduction of the frame weight while conforming with structural integrity requirements, through an integrated approach involving topology optimization, part consolidation and design for additive manufacturing (DFAM). Commercial UAV designs consist of multiple parts and fastening elements that necessitate considerable time and effort for assembly. This study reengineers the frame as a monocoque structure with desirable outcomes of weight reduction and less assembly time. The reengineered Quadcopter structure is manufactured through Fused Filament Fabrication (FFF) and characterized with reference to structural, vibrational and fatigue characteristics. Concomitant application of modal analysis, computational fluid dynamics and wind tunnel testing reveals close match between theoretical estimates and experimental results. Assembly and field trials of the monocoque Quadcopter structure affirm betterment of operational superiority and endurance vis-a-vis commercial UAV designs.
Patient-specific implants are well known for fixing the fracture for bone repairs. However, the exact fixation of the fabricated implant to the patients is a challenging task. To overcome this problem, in the present study two kinds of designs are developed and fabricated. Based on the exact fitting to the patient’s oral system, the best design is selected to fabricate. Computed tomography (CT) scan data of the patient oral anatomy is converted into a 3D model using the DICOM Software “Slicer 3D.” The patient-specific maxillofacial implant is fabricated using fused filament fabrication (FFF) and direct metal laser sintering (DMLS) techniques. Before fabricating real time product, a prototype is fabricated at the initial stage using FFF. Later, stress distribution and displacement of the implant was investigated using a FEM simulation. The conclusion of the present work results are potential for FFF of patient-specific implants out of Ti-6Al-4V.
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