Integrating Additive Manufacturing and Composite Manufacturing Techniques to Build a General-Purpose UAV

Abstract

The development of unmanned aerial vehicles (UAVs) and their integration into our daily life have rapidly accelerated in recent years. Despite these advancements, the production of UAVs often requires specialized and costly equipment. However, with the rapid evolution of additive manufacturing (AM) technologies, it is now possible to design lightweight, optimized structures that can be manufactured easily and quickly. This approach enables faster design iterations, reduces the need for multiple parts and material usage during production, and significantly minimizes waste. A hybrid UAV combines the advantages of vertical take-off and landing (VTOL) capabilities with the efficient cruising performance of a fixed-wing aircraft. This study investigates the feasibility of using AM for the manufacturing of a 3.8-meter wingspan hybrid UAV. The system consists of two components: a hybrid aircraft and a parachute drone carried by the hybrid aircraft. Following the mechanical and aerodynamic design of the air vehicle, it was fabricated using a rapid prototyping approach that integrates AM and composite production techniques. This study demonstrates that even large-scale UAVs can be produced with AM-supported design and manufacturing. This method supports on-demand customization, reduces material waste, and promotes innovation and sustainability in UAV production. It is anticipated that this approach can make UAV production more accessible to the general public, potentially accelerating the development of UAV technology.