Optimization Design of Lightweight 3D-Printed Carbon Fiber Drone Frames: A Computational and Experimental Study

Drones are essential tools in various industries, but optimizing their structural integrity while minimizing weight remains a significant challenge. This study introduces a novel, integrated computational framework for designing lightweight and robust drone frames by combining Computational Fluid Dynamics (CFD), Finite Element Analysis (FEA), and topology optimization. Unlike previous studies that address these aspects separately, the proposed approach unifies aerodynamic and structural performance evaluation to drive the design process. The commercial F450 drone was selected as a benchmark to validate the proposed optimization framework. The study used CFD simulations to assess aerodynamic efficiency and identify dynamic forces, while FEA and topology optimization were used to refine the frame structure, ensuring a lightweight yet robust design. The optimized frame was then fabricated using a novel 3D composite printing with short and Continuous Carbon Fiber (CCF) reinforcements, achieving a 40% reduction in weight without compromising mechanical strength or aerodynamic performance. Real-world flight tests demonstrated that the optimized frame improves energy efficiency, flight stability, and structural durability, leading to extended operational endurance. Compared with its commercial counterpart, the optimized drone achieved a 28% increase in flight time and a 36% improvement in payload capacity.