Design of thermoplastic composite structural parts of unmanned aerial vehicles with topology optimization method and analysis of production conditions with additive manufacturing method

In this research, implemented a 'hexagonal' shaped frame with a size range of less than 375*375*45 mm hexacopter by utilizing topology optimization. During the study, three different materials were utilized: ABS (Acrylonitrile Butadiene Styrene), CF ABS (Carbon Fiber Reinforced ABS), and ONYX. The mechanical characteristics of aerospace goods, topology optimization for mass reduction, and mechanical property enhancement for perfect mechanical performance were the goals of the analytical and numerical analyses conducted for this thesis. Calculations using the aforementioned materials were done based on various production factors. Print orientation and filling density ratio were these production variables that could be controlled. Finite element analyses were performed in addition to analytical modeling, and a chosen product was subjected to topology optimization by assigning various polymer and polymer matrix material attributes created via material extrusion-based additive manufacturing. The geometries that arise from topological optimizations with the same element type and dimensions, loading conditions, and mass reduction target are discussed in terms of their final volumes, which are not included in the optimization goals and constraints