Engineering Design and Analysis of Quadcopter Airframe

Tan, Czech Jiagin (2025) Engineering Design and Analysis of Quadcopter Airframe. Final Year Project (Bachelor), Tunku Abdul Rahman University of Management and Technology.

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Abstract

In the context of unmanned aerial vehicle (UAV) development, achieving a structurally robust yet lightweight airframe is fundamental to enhancing flight endurance, payload efficiency, and aerodynamic performance. This research presents the design, topology optimization, and multiphysics validation of a delivery quadcopter airframe using three candidate materials: Carbon Fiber, AL6061-T6, and Acrylonitrile Butadiene Styrene (ABS). Finite element simulations identified Carbon Fiber as the most suitable material, demonstrating superior stiffness with a maximum total deformation of 13.2 μm, low equivalent strain of 46.7 με, and a remarkably high safety factor of 156, at a moderate mass of 3.76 kg. To minimize structural mass while preserving mechanical integrity, topology optimization was conducted at multiple reduction levels (15%, 30%, 45%, and 60%). Among these, the 45% mass-reduced Carbon Fiber model was selected as optimal, achieving a 42.3% weight reduction with minimal structural trade-off—total deformation increased marginally to 23.31 μm, while equivalent stress and strain remained nearly unchanged at 5109.39 kPa and 46.67 με, respectively. The structural reliability of the optimized model was further validated via a velocity-based drop test simulating a 20-meter fall, where it maintained purely elastic deformation with a safety factor of 1.20, compared to the unoptimized model’s 1.26. This confirmed the optimized design’s resilience against high-impact conditions. Computational fluid dynamics (CFD) analysis, performed under a forward flight condition of 15 m/s, revealed that the optimized design achieved an 18.4% reduction in drag force—from 9.17Nto 7.48N—primarily due to airflow improvements induced by the topologically refined arm structures. Additionally, net pressure drag decreased by 7.8%, frontal stagnation pressure increased by 4.2%, and aft wake pressure was reduced by 17.9%, all indicating smoother rear flow recovery and reduced wake suction. These findings substantiate that the 45% topology-optimized Carbon Fiber configuration successfully achieves the core objectives of this research, delivering substantial mass reduction with minimal compromise in structural integrity, alongside marked improvements in aerodynamic performance. The resulting airframe design offers a well-balanced solution for delivery UAV applications, integrating material efficiency, mechanical resilience, and aerodynamic optimization suitable for real-world implementation.