Integrating Generative Design and Additive Manufacturing for Lightweight UAV Component Development

Year 2025, Volume: 9 Issue: 1st Future of Vehicles Conf., 52 - 59, 17.12.2025

Eszter Borsodi , Agnes Takacs

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

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

Biomimetics , Component design , Drone , Generative design , Mechanical design , Unmanned aerial vehicle

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