Material selection and optimisation of a 3D-printed indoor aerial robotics platform

¹ Centre for Robotics and Future Production, Future Production: Manufacturing, CSIR, South Africa
² Industry Connect, Future Production: Manufacturing, CSIR, South Africa
³ Photonics Centre, Future Production: Manufacturing, CSIR, South Africa

^* Corresponding author: wderonde@csir.co.za

Abstract

Both aerial robotic platforms and additive manufacturing (AM) have become more affordable to consumers. Indoor aerial robotic platforms are typically small and lightweight, while AM is renowned for creating small, high-strength prototypes and components. This paper discusses the material selection and structural optimisation of a 3D-printed indoor aerial robotic platform. Three commonly used AM materials were compared using finite element analysis (FEA): acrylonitrile butadiene styrene (ABS), polyethylene terephthalate glycol (PETG), and Nylon. It was found that Nylon offered the best performance in terms of the strength-to-weight ratio. The aerial robotic frame was optimised using an iterative design approach and previous knowledge with regards to the breaks observed during flight crashes. A dynamic FEA was performed to simulate a drop test from a height of one meter to compare the optimised design with the previous frame design. It was found that the improvements in the redesign have led to a 13.67 % decrease in weight and a 11.78 % decrease stress of the aerial robotic frame. This not only demonstrates the effectiveness of design optimisation, but also highlights the commitment to producing more efficient, reliable and sustainable designs.