DESIGN OF AN EDUCATIONAL MINI DRONE SPECIFICALLY ENGINEERED FOR 3D PRINTING WITH OPTIMAL STRUCTURAL STRENGTH

Abstract

The development of mini drones as educational platforms in engineering disciplines requires a frame design that is lightweight, manufacturable, and structurally reliable. Additive manufacturing using Fused Deposition Modeling (FDM) provides high design flexibility and cost efficiency; However, the mechanical performance of 3D-printed structures is strongly influenced by their geometric configuration. Therefore, a dedicated design approach is required to ensure sufficient structural strength for educational mini drone frames fabricated using FDM. This study aims to design and evaluate a 3D-printed educational mini drone frame made of polyethylene terephthalate glycol (PETG) with optimized structural performance. The research methodology includes computer-aided design (CAD)–based geometric modeling, analytical calculations using classical mechanics of materials, static load testing, and numerical simulation using Finite Element Analysis (FEA) in SolidWorks Simulation. The structural response was evaluated in terms of displacement, Von Mises stress, strain, and factor of safety. The simulation results indicate a maximum displacement of 1.31 mm, a maximum Von Mises stress of 49,417 MPa, and a maximum equivalent strain of approximately 0.0235 (2.35%). The minimum factor of safety was found to be 1.00, while the maximum value reached 5.34. A comparison between analytical and FEA results shows consistent structural response trends, although numerical differences occur due to three-dimensional geometric effects and local stress concentrations. Overall, the proposed mini drone frame is structurally feasible for educational applications and provides a reliable basis for further design optimization, particularly in the central body region.