Session: 03-07-01: Innovative Product Design and Manufacturing

Paper Number: 111791

111791 - Design Optimization of Hexacopter Frame Using Generative Design and Additive Manufacturing 

The field of unmanned aerial vehicles (UAVs) has seen rapid growth in recent years, with applications ranging from aerial photography and surveying to package delivery and search and rescue missions. One of the most popular types of UAVs is the hexacopter, a drone with six rotors that provide it with greater stability and maneuverability compared to quadcopters or other multirotor designs. However, traditional hexacopter designs often suffer from issues such as weight restrictions, limited payload capacity, and structural weaknesses. To address these challenges, this study explores the use of generative design and additive manufacturing techniques to improve the performance of hexacopter.

Generative design is a process that uses computer algorithms to create optimized designs based on user-specified criteria, such as weight reduction or material usage. By utilizing generative design techniques, it is possible to create complex geometries that are not feasible with traditional design methods. Additive manufacturing, on the other hand, refers to the process of creating 3D objects by adding material layer by layer. Additive manufacturing offers several advantages over traditional manufacturing methods, including the ability to produce complex shapes with high precision, reduced lead times, and reduced waste. In this study, a generative design algorithm was used to create an optimized hexacopter frame design that is both lightweight and structurally strong. The algorithm was set to minimize the weight of the hexacopter frame while maintaining its structural integrity and payload capacity. The resulting design was then manufactured using additive manufacturing techniques, specifically Fused Deposition Modeling (FDM), to create a strong and durable frame that is capable of withstanding the stresses of flight. 

This study demonstrates the potential of generative design and additive manufacturing techniques for improving the performance of hexacopter and other UAVs. The optimization process involved comparing various properties such as weight, factor of safety, von Mises stress, and material used. A static simulation was also conducted to evaluate the performance of the optimized frame. By leveraging these technologies, it is possible to create lightweight and structurally strong designs that offer greater stability, maneuverability, and payload capacity compared to traditional designs. These findings can be applied to various applications of UAVs, including aerial photography, surveying, and delivery services.

In conclusion, the results of this study indicate that the use of generative design and additive manufacturing can lead to significant improvements in the performance of hexacopter and other UAVs. As these technologies continue to advance, it is likely that we will see more innovative and efficient designs that push the boundaries of what is possible with UAVs.

 

Presenting Author: Thirumal Azhagan College of Engineering Guindy, Anna University

Presenting Author Biography: Dr. M. Thirumal Azhagan received his B.E. Degree from Bharatiar University, India. He then received both his M.E. Degree and Ph.D Degree from Anna University, India. Since 2007, he is employed as a faculty in Anna University, India. He is currently an Associate Professor at the Department of Manufacturing Engineering, College of Engineering Guindy Campus, Anna University. His current research interests include squeeze casting, composite materials, ultrasonic manufacturing, additive manufacturing and optimization methods. He has published 25 research papers in reputed Journals and presented his research findings in several International Conferences held in India and abroad.

Authors:

Thirumal Azhagan M. College of Engineering Guindy, Anna University
Ragavanantham Shanmugam Fairmont State University
Saquib Khan Maharaja Agrasen Institute of Technology
Surabhi Lata Maharaja Agrasen Institute of Technology