A Comparison between 3D Printing and Milling Process for a Spar Cap Fitting (Wing-fuselage) of UAV Aircraft

Ferro, C.; Mazza, Andrea; Belmonte, Dario; Seclì, Carlo; Maggiore, Paolo

doi:10.1016/j.procir.2016.06.028

Cited by 12 publications

(8 citation statements)

References 7 publications

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“…In the last years, this technique has been considered also for low scale mass production due to some advantages [12]. Firstly, this technique allows the construction of so-called evolutive shapes: structures of com- plex design that are impossible or difficult to build with traditional milling or machining [36]. Evolutive shapes are usually the result of a topological optimization.…”

Section: D Printing and Fdm Technologymentioning

confidence: 99%

A multipurpose modular drone with adjustable arms produced via the FDM additive manufacturing process

Brischetto

Ciano

Ferro

2016

Curved and Layered Structures

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The present paper shows an innovative multirotor Unmanned Aerial Vehicle (UAV) which is able to easily and quickly change its configuration. In order to satisfy this feature, the principal structure is made of an universal plate, combined with a circular ring, to create a rail guide able to host the arms, in a variable number from 3 to 8, and the legs. The arms are adjustable and contain all the avionic and motor drivers to connect the main structure with each electric motor. The unique arm design, defined as all-in-one, allows classical single rotor configurations, double rotor configurations and amphibious configurations including inflatable elements positioned at the bottom of the arms. The proposed multi-rotor system is inexpensive because of the few universal pieces needed to compose the platform which allows the creation of a kit. This modular kit allows to have a modular drone with different configurations. Such configurations are distinguished among them for the number of arms, number of legs, number of rotors and motors, and landing capability. Another innovation feature is the introduction of the 3D printing technology to produce all the structural elements. In this manner, all the pieces are designed to be produced via the Fused Deposition Modelling (FDM) technology using desktop 3D printers. Therefore, an universal, dynamic and economic multi-rotor UAV has been developed.

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Section: D Printing and Fdm Technologymentioning

confidence: 99%

A multipurpose modular drone with adjustable arms produced via the FDM additive manufacturing process

Brischetto

Ciano

Ferro

2016

Curved and Layered Structures

Self Cite

View full text Add to dashboard Cite

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“…Additionally, lightweight metal alloys and injectionmolded foam were also used to reduce the weight and improve the UAV strength and stiffness. 12 Afterwards, Ferro et al 13,14 combined the topology optimization method with 3D printing technology to manufacture the complex and lightweight UAV frame. Topology optimization has been implemented as a powerful structural design method in engineering applications at the early stage of the design process, because it can generate lightweight and innovative layouts for product design.…”

Section: Introductionmentioning

confidence: 99%

Lightweight and maintainable rotary-wing UAV frame from configurable design to detailed design

Guo

Sun

et al. 2021

Advances in Mechanical Engineering

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Rotary-wing unmanned aerial vehicles (UAVs) are widespread in both the military and civilian applications. However, there are still some problems for the UAV design such as the long design period, high manufacturing cost, and difficulty in maintenance. Therefore, this paper proposes a novel design method to obtain a lightweight and maintainable UAV frame from configurable design to detailed design. First, configurable design is implemented to determine the initial design domain of the UAV frame. Second, topology optimization method based on inertia relief theory is used to transform the initial geometric model into the UAV frame structure. Third, process design is considered to improve the manufacturability and maintainability of the UAV frame. Finally, dynamic drop test is used to validate the crashworthiness of the UAV frame. Therefore, a lightweight UAV frame structure composed of thin-walled parts can be obtained and the design period can be greatly reduced via the proposed method.

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“…There are some articles related to joints, e.g. wing-fuselage joint (Ferro et al , 2017) or on manufacturing small details, e.g. fittings (Mieloszyk et al , 2018) but there is very difficult to find article on entire structure manufactured using 3D printing.…”

Section: Introductionmentioning

confidence: 99%

FDM 3D printing method utility assessment in small RC aircraft design

Skawiński

Goetzendorf‐Grabowski

2019

AEAT

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Purpose The purpose of this paper is to investigate the possibility of manufacturing fused deposition modelling (FDM) 3D printed structures such as wings or fuselages for small remote control (RC) air craft and mini unmaned aerial vehicles (UAVs). Design/methodology/approach Material tests, design assumptions and calculations were verified by designing and manufacturing a small radio-controlled motor-glider using as many printed parts as possible and performing test flights. Findings It is possible to create an aircraft with good flight characteristics using FDM 3D printed parts. Current level of technology allows for reasonably fast manufacturing of 3D printed aircraft with good reliability and high success ratio of prints; however, only some of the materials are suitable for printing thin wall structures such as wings. Practical implications The paper proves that apart from currently popular small RC aircraft structural materials such as composites, wood and foam, there is also printed plastic. Moreover, 3D printing is highly competitive in some aspects such as first unit production time or production cost. Originality/value The presented manufacturing technique can be useful for quick and cost-effective creating scale prototypes of the aircraft for performing test flights.

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A Comparison between 3D Printing and Milling Process for a Spar Cap Fitting (Wing-fuselage) of UAV Aircraft

Cited by 12 publications

References 7 publications

A multipurpose modular drone with adjustable arms produced via the FDM additive manufacturing process

A multipurpose modular drone with adjustable arms produced via the FDM additive manufacturing process

Lightweight and maintainable rotary-wing UAV frame from configurable design to detailed design

FDM 3D printing method utility assessment in small RC aircraft design

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