Session: ASME Undergraduate Student Design Expo

Paper Number: 166891

Design, Build and Fly a 3d-Printed Uav (Unmaned Aerial Vehicle) 

Using 3D printing technology to construct RC airplanes provides precise control over geometry, weight distribution, material properties, etc. This also allows for rapid prototyping, the use of complex geometries, and cost-effective manufacturing processes.

The goal of this work is to implement new design ideas and manufacturing processes to design, build, and fly a 3D-printed RC airplane. The fundamental approach applied in this design is to minimize the usage of commercial parts while increasing the strength and rigidity of the airplane through design ideas, improving transportability implementing modular design, and yet making the plane functional giving good aerodynamic performance.

The highlight of our approach is the modular design for the aircraft wings. This innovative approach solves two of the major problems associated with manufacturing large RC airplanes with conventional small 3D printers and then transporting the airplane for flights.   Each wing is broken into three smaller airfoils for easier manufacturability and transportability. Small slots will be used instead of screws or adhesives to connect the portions to provide a rigid connection and reduce the weight of the aircraft. Instead of using typical male-female joints, a rather different female-male-female joint will be used allowing maximum usage of printer size. The modular system also allows for easy maintenance, as we can replace the individual portions in case of damage. This approach will also reduce the cost.

Another significant design approach taken is using honeycomb structures inside the wing to increase the strength of the airplane. This honeycomb structure allows significant rigidity, which is fundamentally important to maintain the aerodynamic profile of the wing while reducing the weight of the airplane. Figure 1 shows the honeycomb structure and different modular sections of the wing.

PLA and lightweight PLA is being used as the 3D printing material to ensure strength while minimizing weight, and each joint will be optimized to reduce drag and improve airflow. The initial design is done in SolidWorks, and then the aircraft is printed in BambuLab X1 Carbon printer. BambuLab X1C 3D printer is used for printing the parts of the aircraft. One of the challenges of this printer is its printing volume. The maximum length the printer can print is 250 mm. However, our modular design concept allowed us to overcome this challenge.

The development of our 3D-printed RC airplane shows the potential of modern additive manufacturing processes in designing and making such aircraft. By incorporating honeycomb structures in the wings and modular sections of the wings, we successfully addressed key challenges related to manufacturability, transportability, and structural rigidity. Other design choices like using foldable propellers, using female-male-female joints have also made the manufacturing process easier and the aircraft aerodynamically functional at the same time. This project not only highlights the feasibility of using 3d printers to make RC aircraft but also opens the future possibility of making more UAVs and experimental aircraft design.

Presenting Author: Md Azizul Islam Tennessee Technological University

Presenting Author Biography: Md Azizul Islam is a seasoned and accomplished aeronautics and aerodynamics professional with extensive expertise in UAV (Unmanned Aerial Vehicle) design and development. He earned his undergraduate degree in Naval Architecture and Marine Engineering from the prestigious Bangladesh University of Engineering and Technology (BUET). With over 16 years of hands-on experience designing, building, and flying various UAVs, Md Azizul has demonstrated exceptional technical insight and innovation in aerospace engineering applications. Currently, Md Azizul serves as a pioneering graduate research assistant at Tennessee Tech University (TTU), where he is pioneering work in morphing UAVs. His research combines cutting-edge aerodynamics, lightweight structural design, and advanced composite material applications to develop UAVs capable of dynamic shape adaptation for improved performance and versatility.
Md Azizul’s deep commitment to innovation is evident in his extensive portfolio of UAV projects and his focus on engineering solutions that enhance efficiency, adaptability, and sustainability. His expertise spans multiple domains, including 1) UAV flight dynamics and control systems, 2) morphing technology integration, and 3) advanced manufacturing techniques like 3D printing.
A dedicated researcher and engineer, Md Azizul Islam is passionate about pushing the boundaries of engineering to create transformative solutions. His work is driven by a profound belief in the power of technology to redefine possibilities in aerospace and aeronautics engineering, and his contributions continue to leave a significant mark on these fields.

Authors:

Tanner Welch Tennessee Technological University
Kayla Kohr Tennessee Technological University
Azizur Rahman Tennessee Technological University
Md Azizul Islam Tennessee Technological University
Achintya Saha Tennessee Technological University
Bruce Jo Tennessee Technological University