Topology Optimization for Drone Structure: Comprehensive Workflow Including Conceptual Modeling, Components Preparation and Additive Manufacturing

Abstract

Payload drones are often limited more by frame weight than by motor power. This work aims to design, optimize, and validate a flat octocopter frame with eight independently driven rotors arranged symmetrically on separate arms. The drone frame design in SOLIDWORKS uses Finite Element Analysis (FEA) and topology optimization to remove material from low-stress regions while keeping the main load paths intact. The final design cuts the frame mass by 37.3% compared to the baseline model and reduces the 3D printing time by about five hours using a Creality K1C printer with Polylactic Acid (PLA) filament. These changes increase the available thrust-to-weight margin for payload without exceeding the allowable stress or deformation limits of the material. The electronic components also identified compatible flight controllers, ESCs, motors, and radio systems to show that the proposed frame can be integrated into a complete multirotor platform. Overall, this work demonstrates a practical approach to designing lighter octocopter frames that are easier to 3D print and can be used more effectively for delivery and inspection missions.

Keywords

Finite Element Analysis (FEA) / Fused Deposition Modeling (FDM) / Octocopter / Polylactic Acid (PLA) / Topology Optimization (TO) / SOLIDWORKS / Solid Isotropic Material with Penalization (SIMP) / UAVs

Statement of the Use of Generative AI and AI-Assisted Technologies in the Writing Process

During the preparation of this manuscript, the author(s) used ChatGPT and Gemini in order to language editing, idea structuring and grammar checking. After using this tools, the author(s) reviewed and edited the content as needed and take full responsibility for the content of the published article.

Acknowledgments

We would like to acknowledge Simon Anandaraj Doss, Seerla Kanagarajoo, and Chew Zhe Zhi for their valuable assistance with 3D printing.

Author Contributions

Conceptualization, H.O.Y.O. and H.S.C.; Methodology, H.O.Y.O. and J.T.; Software, H.O.Y.O., M.A.A.A. and J.T.; Validation, H.S.C., H.O.Y.O. and A.O.M.; Formal Analysis, H.O.Y.O. and J.T.; Investigation, H.S.C. and H.O.Y.O.; Resources, N.R.R.R.; Data Curation, H.O.Y.O. and M.A.A.A.; Writing—Original Draft Preparation, H.O.Y.O. and J.T.; Writing—Review & Editing, H.S.C. and A.O.M.; Visualization, H.O.Y.O. and H.S.C.; Supervision, N.R.R.R., H.S.C. and K.M.Y.; Project Administration, H.O.Y.O. and H.S.C.; Funding Acquisition, H.S.C.

Ethics Statement

Not applicable.

Informed Consent Statement

Not applicable.

Data Availability Statement

Data available from the corresponding author on request.

Funding

This work was supported by the University of Wollongong Malaysia, Postgraduate and Research Centre (PGRC), based in Utropolis Glenmarie, Malaysia and Sunway University Postgraduate Studentship.

Declaration of Competing Interest

The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.

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