Project Overview
Designing an aerospace frame requires an aggressive balance between strength and weight. This personal project focused on designing, simulating, and 3D printing an ultra-lightweight chassis for a high-performance racing micro-drone. The design philosophy heavily relied on minimizing aerodynamic drag while maximizing the structural rigidity needed to withstand high-G maneuvers.
The initial CAD was developed in Fusion 360, where we applied Generative Design and topology optimization algorithms. By defining specific load cases—such as motor thrust vectors, battery weight, and anticipated impact forces—the software organically removed non-critical material. This resulted in an alien-like, highly optimized geometry that shed 35% of the original mass.
Manufacturing the frame presented its own challenges. We utilized Fused Deposition Modeling (FDM) with advanced carbon-fiber infused PLA to achieve the necessary strength-to-weight ratio. Following fabrication, the frames were subjected to rigorous real-world drop tests, iterative redesigns, and final flight validation.
Key Contributions
- Utilized advanced generative design and topology optimization algorithms in Fusion 360 to achieve maximum mass reduction while maintaining stiffness.
- Manufactured the optimized frame prototypes iteratively using FDM 3D printing with lightweight, durable carbon-fiber infused PLA.
- Subjected prototypes to rigorous real-world drop-test survival metrics, iteratively refining the design until critical failure points were eliminated.