Novel Mechanical Design, Simulation, and CFD Analysis of a DNA-Shaped Quadcopter Fabricated through Additive Manufacturing

Abstract

This paper proposes the design, fabrication, and static and computational fluid dynamics (CFD) analysis of a quadcopter with a unique structure. In contrast to traditional unmanned aerial vehicles (UAVs), the arms of the quadcopter are designed in the shape of a deoxyribonucleic acid (DNA) helix. Customization of the quadcopter is merged with additive manufacturing technology; its all-skeletal components are fabricated with acrylonitrile butadiene styrene material utilizing the fused deposition modeling technique. This design technology contributes to additional customization by diversifying the quadcopter's applicability scenarios. Although the propellers have a significant impact on the movement of the UAV, the rotation of the propeller generates thrust in the axial direction of the quadcopter and is therefore a vital aspect of the quadcopter's fabrication process. In order to calculate this thrust, CFD analysis is performed on the quadcopter and its propellers. In addition, the finite element method (FEM) is applied to the structural analysis of the DNA-shaped quadcopter's (DNASQ) skeletal structure and components, and CFD is utilized to examine the impact of the quadcopter's body during airflow. Based on the results of the structural assessment, it is determined that the structure's completion would allow the weight of the avionics system to compensate for the impact accurately. According to the aerodynamic analysis, the drag force of the DNASQ is computed as 7.358 N, and the drag coefficient is calculated as 0.6656. After analyzing propeller thrust with the FEM at various rotational speeds, the highest thrust force is determined as 31.806 N at a rotating speed of 8,450 rpm (rev/min). Based on the results, it is clear that the propeller can generate the required thrust to lift the quadcopter and sustain dynamic loading without any failure.