Minimal Surfaces as an Innovative Solution for the Design of an Additive Manufactured Solar-Powered Unmanned Aerial Vehicle (UAV)

Abstract

This paper aims to describe the methodology used in the design and manufacture of a fixed-wing aircraft manufactured using additive techniques together with the implementation of technology based on solar panels. The main objective is increasing the autonomy and range of the UAV’s autonomous missions. Moreover, one of the main targets is to improve the capabilities of the aeronautical industry towards sustainable aircrafts and to acquire better mechanical properties owing to the use of additive technologies and new printing materials. Further, a lower environmental impact could be achieved through the use of renewable energies. Material extrusion (MEX) technology may be able to be used for the manufacture of stronger and lighter parts by using gyroids as the filling of the printed material. The paper proposes the use of minimal surfaces for the reinforcement of the UAV aircraft wings. This type of surface was never used because it is not possible to manufacture it using conventional techniques. The rapid growth of additive technologies led to many expectations for new design methodologies in the aeronautical industry. In this study, mechanical tests were carried out on specimens manufactured with different geometries to address the design and manufacture of a UAV as a demonstrator. In addition, to carry out the manufacture of the prototype, a 3D printer with a movable bench similar to a belt, that allows for the manufacture of parts without limitations in the Z axis, was tested. The parts manufactured with this technique can be structurally improved, and it is possible to avoid manufacturing multiple prints of small parts of the aircraft that will have to be glued later, decreasing the mechanical properties of the UAV. The conceptual design and manufacturing of a solar aircraft, SolarÍO, using additive technologies, is presented. A study of the most innovative 3D printers was carried out that allowed for the manufacture of parts with an infinite Z-axis and, in addition, a filler based on minimal surfaces (gyroids) was applied, which considerably increased the mechanical properties of the printed parts. Finally, it can be stated that in this article, the potential of the additive manufacturing as a new manufacturing process for small aircrafts and for the aeronautical sector in the future when new materials and more efficient additive manufacturing processes are already developed is demonstrated.

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A Study on Mechanical Properties of Low-Cost Thermoplastic-Based Materials for Material Extrusion Additive Manufacturing

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Composite Material Testing for UAV Development

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