04.1 - Aerospace Grade Materials, Structural Analysis, Fatigue and Damage Tolerance

OPTIMIZATION OF INTERCONNECTED 3D-PRINTED STRUCTURES FOR UAVS

C.D. Scott¹, A.M. Comer¹, J.C. Hanan¹, A. Nunley¹; ¹Oklahoma State University, United States

This work presents a stress-driven topology-optimization workflow that turns printer-size PETG modules into large, flight-testable Group 1-2 UAV structures. Dovetail joints enable fast field replacement of damaged sections. Planned load tests and CT/SEM will quantify strength and porosity. The same approach can cut cost/time for robotics, marine, and space structures.

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DOI: 10.71945/icas2026_0943