Integrating Generative Design and Additive Manufacturing for Lightweight UAV Component Development

Eszter Borsodi; Agnes Takacs

doi:10.30939/ijastech..1754843

Integrating Generative Design and Additive Manufacturing for Lightweight UAV Component Development

Abstract

The development of additive manufacturing technologies, which build objects layer by layer, has enabled the realization of structures with complex, biomimetic geometries created by generative design. Generative design is an algorithmic design method that results in a model optimized for predefined requirements, the so-called generative parameters. The synergy between generative design and additive manufacturing can open a new dimension in the development of lightweight components, as generative design can reduce the mass of components while maintaining or even improving their mechanical properties. This feature is particularly valuable in the design of aerial vehicle parts, where payload capacity and flight time are critical metrics. Unmanned Aerial Vehicles (UAVs) are used in several areas, including precision agriculture, surveillance, and transportation in logistics systems. The rapid spread of UAVs necessitates research focused on the lightweight structural optimization of their components through advanced design to improve overall flight performance. This paper presents a case study of a UAV arm that was constructed using generative design to reduce its mass. The most important generative parameters, constraints, and forces were determined based on a critical case, a worst-case scenario. Utilising generative design, a 10% mass reduction was achieved. Finite element analysis was demonstrated that the generatively designed arm produces similar total deformation and equivalent stress results compared to the original arm. Achieving a 10% weight reduction for all four arms of the quadcopter can lead to a significant overall mass decrease, contributing to improved energy efficiency.

Keywords

References

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Details

Primary Language

English

Subjects

Automotive Engineering (Other)

Journal Section

Research Article

Authors

Eszter Borsodi ^*
0000-0002-3955-2182
Hungary

Agnes Takacs
0000-0002-3210-6964
Hungary

Early Pub Date

November 19, 2025

Publication Date

December 17, 2025

Submission Date

July 31, 2025

Acceptance Date

November 18, 2025

Published in Issue

Year 2025 Volume: 9 Number: 1st Future of Vehicles Conf.

DOI

https://doi.org/10.30939/ijastech..1754843

IZ

https://izlik.org/JA56EK93ZF

Cite

RIS / Bibtex

APA

Borsodi, E., & Takacs, A. (2025). Integrating Generative Design and Additive Manufacturing for Lightweight UAV Component Development. International Journal of Automotive Science And Technology, 9(1st Future of Vehicles Conf.), 52-59. https://doi.org/10.30939/ijastech..1754843

AMA

1.Borsodi E, Takacs A. Integrating Generative Design and Additive Manufacturing for Lightweight UAV Component Development. IJASTECH. 2025;9(1st Future of Vehicles Conf.):52-59. doi:10.30939/ijastech.1754843

Chicago

Borsodi, Eszter, and Agnes Takacs. 2025. “Integrating Generative Design and Additive Manufacturing for Lightweight UAV Component Development”. International Journal of Automotive Science And Technology 9 (1st Future of Vehicles Conf.): 52-59. https://doi.org/10.30939/ijastech. 1754843.

EndNote

Borsodi E, Takacs A (December 1, 2025) Integrating Generative Design and Additive Manufacturing for Lightweight UAV Component Development. International Journal of Automotive Science And Technology 9 1st Future of Vehicles Conf. 52–59.

IEEE

[1]E. Borsodi and A. Takacs, “Integrating Generative Design and Additive Manufacturing for Lightweight UAV Component Development”, IJASTECH, vol. 9, no. 1st Future of Vehicles Conf., pp. 52–59, Dec. 2025, doi: 10.30939/ijastech..1754843.

ISNAD

Borsodi, Eszter - Takacs, Agnes. “Integrating Generative Design and Additive Manufacturing for Lightweight UAV Component Development”. International Journal of Automotive Science And Technology 9/1st Future of Vehicles Conf. (December 1, 2025): 52-59. https://doi.org/10.30939/ijastech. 1754843.

JAMA

1.Borsodi E, Takacs A. Integrating Generative Design and Additive Manufacturing for Lightweight UAV Component Development. IJASTECH. 2025;9:52–59.

MLA

Borsodi, Eszter, and Agnes Takacs. “Integrating Generative Design and Additive Manufacturing for Lightweight UAV Component Development”. International Journal of Automotive Science And Technology, vol. 9, no. 1st Future of Vehicles Conf., Dec. 2025, pp. 52-59, doi:10.30939/ijastech. 1754843.

Vancouver

1.Eszter Borsodi, Agnes Takacs. Integrating Generative Design and Additive Manufacturing for Lightweight UAV Component Development. IJASTECH. 2025 Dec. 1;9(1st Future of Vehicles Conf.):52-9. doi:10.30939/ijastech. 1754843