An Integrated TO–DfAM Approach for the Lightweight Structural Design of UAV Gimbal Carriers

Neslihan Top

An Integrated TO–DfAM Approach for the Lightweight Structural Design of UAV Gimbal Carriers

Abstract

The rapid development of additive manufacturing technologies, supported by new processes and materials, necessitates the restructuring of product development and design workflows to maximize their advantages. In this study, a camera positioning component used in unmanned aerial vehicles (UAVs) was redesigned using a topology optimization approach. The adopted design methodology aims to reduce volume in low-stress regions while also considering the geometric limitations of additive manufacturing systems. The optimized component obtained through the integrated design process was found to have lower weight and better structural integrity compared to its conventionally manufactured counterparts. Finite element analyses performed using AlSi10Mg alloy and Selective Laser Melting (SLM) revealed that the optimized design achieved approximately a 38% reduction in mass compared to the initial geometry, while fully preserving structural integrity. The maximum equivalent (von Mises) stress value remained at 11.8 MPa, and the total displacement values were within acceptable limits.

Keywords

Topology optimisation , Structural analysis , Product design , Additive manufacturing

References

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Details

Primary Language

English

Subjects

Optimization Techniques in Mechanical Engineering

Journal Section

Research Article

Authors

Neslihan Top ^*
0000-0002-0771-6963
Türkiye

Publication Date

December 31, 2025

Submission Date

December 3, 2025

Acceptance Date

December 29, 2025

Published in Issue

Year 2025 Volume: 11 Number: 3

IZ

https://izlik.org/JA36TW83GT

IEEE

[1]N. Top, “An Integrated TO–DfAM Approach for the Lightweight Structural Design of UAV Gimbal Carriers”, GJES, vol. 11, no. 3, pp. 414–425, Dec. 2025, [Online]. Available: https://izlik.org/JA36TW83GT

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