Design and Optimization of a Lightweight Drone using Additive Manufacturing with Topology and Parametric Optimization

Abstract

Department of Mechanical Engineering School of Engineering UB Rise 2025This research focuses on the design, optimization, and fabrication of a lightweight drone using Additive Manufacturing (AM) with Topology and Parametric Optimization. Finite Element Analysis (FEA) facilitated a 65% weight reduction while maintaining structural integrity and optimal flight performance. Polylactic Acid (PLA) was chosen for its lightweight properties and 3D printability. Topology optimization minimized material usage in non-load-bearing regions, while parametric optimization refined the geometry for improved aerodynamics. Flight testing validated the feasibility of AM in efficient drone design, demonstrating its potential in sustainable aerospace applications