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

Year 2025, Volume: 11 Issue: 3, 414 - 425, 31.12.2025

Neslihan Top

https://izlik.org/JA36TW83GT

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

• [1] I. Gibson, D. Rosen, B. Stucker, M. Khorasani, D. Rosen, B. Stucker, & M. Khorasani, Additive manufacturing Technologies, vol. 17, pp. 160-186. Cham, Switzerland: Springer, 2021.
• [2] R. Ramadani, S. Pal, M. Kegl, J. Predan, I. Drstvenšek, S. Pehan, and A. Belšak, “Topology optimization and additive manufacturing in producing lightweight and low vibration gear body,” The International Journal of Advanced Manufacturing Technology, vol. 113, no. 11, pp. 3389–3399, 2021.
• [3] Z. Liu, Y. Xu, and Y. Zhang, “Reliability-based design for lightweight vehicle structures with uncertain manufacturing accuracy,” Applied Mathematical Modelling, vol. 95, pp. 22–37, 2021.
• [4] F. Kateb, A. Haseeb, B. M. Alghamdi, F. Q. Khan, B. Khan, A. Baseer, M. I. Marwat, and S. Jan, “Drone frame optimization via simulation and 3D printing,” Computers, vol. 14, no. 8, p. 328, 2025, doi: 10.3390/computers14080328
• [5] Y. L. Yap, W. Toh, A. Giam, F. R. Yong, K. I. Chan, J. W. S. Tay, S. S. Teong, R. Lin, and T. Y. Ng, “Topology optimization and 3D printing of micro-drone: Numerical design with experimental testing,” International Journal of Mechanical Sciences, vol. 237, p. 107771, 2022. doi: 10.1016/j.ijmecsci.2022.107771
• [6] N. Top, H. Gökçe, and İ. Şahin, “Topology optimization of an additive manufactured UAV catapult bracket using SIMP and BESO methods,” Applied Sciences, vol. 15, no. 23, p. 12477, 2025. doi: 10.3390/app152312477
• [7] M. P. Bendsøe and O. Sigmund, Topology Optimization: Theory, Methods, and Applications. Berlin, Germany: Springer, 2004, pp. 1–69.
• [8] J. D. Deaton and R. V. Grandhi, “A survey of structural and multidisciplinary continuum topology optimization: Post 2000,” Structural and Multidisciplinary Optimization, vol. 49, no. 1, pp. 1–38, 2014.
• [9] K. Liu and A. Tovar, “An efficient 3D topology optimization code written in MATLAB,” Structural and Multidisciplinary Optimization, vol. 50, no. 6, pp. 1175–1196, 2014.
• [10] A. M. Rayed, B. Esakki, A. Ponnambalam, S. C. Banik, and K. Aly, “Optimization of UAV structure and evaluation of vibrational and fatigue characteristics through simulation studies,” International Journal for Simulation and Multidisciplinary Design Optimization, vol. 12, p. 17, 2021.
• [11] J. H. Zhu, W. H. Zhang, and L. Xia, “Topology optimization in aircraft and aerospace structures design,” Archives of Computational Methods in Engineering, vol. 23, no. 4, pp. 595–622, 2016.
• [12] A. Ramos, V. G. Angel, M. Siqueiros, T. Sahagun, L. Gonzalez, and R. Ballesteros, “Reviewing additive manufacturing techniques: Material trends and weight optimization possibilities through innovative printing patterns,” Materials, vol. 18, no. 6, p. 1377, 2024. doi: 10.3390/ma18061377
• [13] L. Schlesinger, J. Koller, M. Pagels, and F. Döper, “Alignment of design rules for additive manufacturing and remanufacturing,” Journal of Remanufacturing, vol. 13, pp. 99–119, 2023. doi: 10.1007/s13243-022-00122-9
• [14] Y. Fu, K. Ghabraie, B. Rolfe, Y. Wang, and L. N. Chiu, “Smooth design of 3D self-supporting topologies using additive manufacturing filter and SEMDOT,” Applied Sciences, vol. 11, no. 1, p. 238, 2020. doi: 10.3390/app11010238
• [15] L. Ye, Y. Zhao, H. Zhang, Y. Zhang, J. Lv, and Z. Yang, “Strength analysis and structural optimization of UAV airframe,” Frontiers in Mechanical Engineering, vol. 11, p. 1708043, 2025. doi: 10.3389/fmech.2025.1708043
• [16] B. Gao, H. Yang, W. Chen, and H. Wang, “Topology optimization of the bracket structure in the acquisition, pointing, and tracking system considering displacement and key point stress constraints,” Aerospace, vol. 11, no. 11, p. 939, 2024. doi: 10.3390/aerospace11110939
• [17] L. Ye, Y. Zhao, H. Zhang, Y. Zhang, J. Lv, and Z. Yang, “Strength analysis and structural optimization of UAV airframe,” Frontiers in Mechanical Engineering, vol. 11, p. 1708043, 2025. doi: 10.3389/fmech.2025.1708043
• [18] L. A. Jaber, A. A. Jaber, W. Giernacki, Z. H. Khan, K. M. Ali, M. A. Tawafik, and A. J. Humaidi, “Quadcopter unmanned aerial vehicle structural design using an integrated approach of topology optimization and additive manufacturing,” Designs, vol. 8, no. 3, p. 58, 2024. doi: 10.3390/designs8030058
• [19] FEDesign, “Design process with ANSYS Workbench and TOSCA Structure,” 2020. [Online]. Available: https://support.ansys.com. Accessed: Sep. 18, 2025.
• [20] M. P. Bendsoe and N. Kikuchi, “Generating optimal topologies in structural design using a homogenization method,” Computer Methods in Applied Mechanics and Engineering, vol. 71, pp. 197–224, 1988.
• [21] Y. M. Xie and G. P. Steven, “A simple evolutionary procedure for structural optimization,” Computers & Structures, vol. 49, pp. 885–896, 1993.
• [22] X. Huang and Y. M. Xie, “Convergent and mesh independent solutions for the bi-directional evolutionary structural optimization method,” Finite Elements in Analysis and Design, vol. 43, no. 14, pp. 1039–1049, 2007.
• [23] G. Allaire, F. Jouve, and A.-M. Toader, “A level-set method for shape optimization,” Comptes Rendus Mathématique, vol. 334, pp. 1125–1130, 2002.
• [24] Neway AeroTech, “AlSi10Mg – Lightweight aluminum alloy optimized for 3D printing.” [Online]. Available: https://www.newayaerotech.com/services/aluminum-3d-printing/alsi10mg. [Accessed: Sep. 9, 2025].
• [25] X. Kong, Y. Wu, P. Zhu, P. Zhi, and Q. Yang, “Novel artificial neural network aided structural topology optimization,” Applied Sciences, vol. 14, no. 23, 2024. doi: 10.3390/app142311416