Economic optimization of drone structure for industrial indoor use by additive manufacturing

The forthcoming industrial environments will require a high level of automation to be flexible. In this sense, Industry 4.0 encourages the integration of new autonomous systems digitally interconnected that can interact with humans. This thesis is developed at CIM 4.0 in the frame of the FIXIT project aiming to produce an autonomous system integrated by a UAV and a UGV. As a result, a combined system that complies with the Industry 4.0 requirements is created and mainly serves an operator by performing inspection tasks. This work is focused on redesigning the UAV airframe by implementing one of the industry 4.0 pillars: additive manufacturing. The topology optimization method is integrated into the design process to create a mass-customized structure with optimum structural properties. The role of Additive manufacturing in this work is crucial to obtain an innovative, customized system with an optimum cost considering the prices on the market. The thesis is performed in different phases, starting from the definition of the UAV configuration and the propulsion system. Then a multi-material comparison and the analysis of different airframe designs are performed considering the cost and structural performance. Following this is the detailed design, in which other necessary features like the landing system, devices’ supports, and protection structures are designed. Finally, is performed the manufacturing phase in which the final design is produced through FDM technology. The result is a lightweight customized airframe with good mechanical properties and optimum cost that is well integrated with the electronic components and landing system, enabling its autonomous performance characterized by repeatability and effectiveness.