Generative design of 6 axis drone for weight optimisation

Kueh, Tze Jun (2021) Generative design of 6 axis drone for weight optimisation. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

A drone is an Unmanned Aerial Vehicle (UAV). UAV drone is a flying robot that can be remotely controlled through software-controlled flight plans in their embedded systems. UAV drones are equipped with varies state of the art technology such as infrared cameras, GPS, and laser (consumer, commercial and military UAV). The nose part of the UAV drone is the location where the sensors and navigational systems located. The objective of this project is to design and fabricate structure of a UAV drone which achieving the optimization of shape of materials and manufacturing methods and saving cost of materials, parts, and design time for industry. Besides, this project also aimed to achieve multiple explorations and validations of product design of UAV drone which accelerating product development process. The major challenge in this project is to obtain unique structure design of the 6-axis drone through different input applied. In this project, a mechanical structure of UAV drone is fabricated are sketched in Autodesk Inventor and Autodesk Fusion 360. Generative Design is a process of defining the constraints and forces of the imaginary design then the software will calculate all the shape possibilities that satisfies the initial design parameters. The UAV Drone designed according to two regions which are obstacle and preserve regions. The preserve regions define as areas that must exist for the part to function properly. Obstacle regions define as areas that need to be avoided by the generated outcome. The load cases will determine where material is added to ensure that the design of UAV drone meets the performance requirements. Structural Constraints include Fixed, Pinned, and Frictionless. Fixed Constraints can be set to the X, Y, and Z aces. There are three manufacturing options which are Unrestricted, Additive, and Subtractive. There are many types of materials such as ABS Plastic, Titanium, and so on. There are objectives either Minimize Mass or Maximize Stiffness and Safety factor must be selected. Exploration tools like detailed thumbnails, filters, and customizable scatter plots help to find the results that best match UAV drone design, engineering, and manufacturing requirements. The prototype of this generative design of 6 axis drone fabricated by using Selective Laser Sintering (SLS) printing with Nylon material. This generative design has total weight less than 1kg. It optimized maximum stress analysis is 5.028MPa with 83.00%, maximum displacement analysis is 0.666mm with 45.44% and production time is 15.5hours with 61.25% which improve the weight optimization.

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