Experimental characterisation and numerical finite element analysis of 3D-printed topology optimised micro-UAV

• Main Author: Yong, Feng Rong
• Other Authors: Ng Teng Yong
• Format: Final Year Project
• Language: English
• Published: Nanyang Technological University 2021
• Subjects: Engineering::Aeronautical engineering
• Online Access: https://hdl.handle.net/10356/150594
• Institution: Nanyang Technological University

Unmanned Aerial Vehicles (UAVs) have been increasingly used in many industries for their customisability to suit needs and applications. Heavily used by the military, micro-UAVs is recognised to be a potential growing segment of UAVs for other industries as well. 3D printing, with the advancement in material development and manufacturing techniques, has the potential to transform from a primary means of rapid prototyping for UAVs to a rapid and on-demand manufacturing alternative. Topology optimisation with 3D printing can greatly streamline the design and manufacturing of UAVs, producing UAV with improved structural performance as compared to the traditionally designed and manufactured UAVs. This project aims to explore the use of topology optimisation and 3D printing for micro-UAVs. Polyamide 12 (Nylon 12), printed using Selective Laser Sintering (SLS), was experimentally characterised through mechanical and ultrasonic testing. Using the transversely isotropic elastic properties obtained from both the tensile and ultrasonic testing, the finite element verification showed a good correlation between the experiment and simulation results of the 3-point and 4-point bending tests. Hence the elastic properties can be reliably used for topology optimisation and numerical analysis in the design of the micro-UAV. Designs were developed in an iterative process and then explored to identify an optimised structure that meets the strict structural requirements of the micro-UAV. The 3D-printed topology optimised micro-UAV structure underwent a loading test for verification with the simulation result and a close correlation was obtained between the numerical and experimental data. The outcome of the topology optimisation with the parametric study is highly satisfactory as the micro-UAV has a significant mass reduction of 28 % from the initial mass requirement while being able to meet structural requirements that were set for this project.