Optimization of 3D Printed Quadcopter Frames for Vibration Reduction: Design and Simulation
Year: 2026
Type: dissertation
Abstract: This project investigates the design and optimization of 3D printed quadcopter frames with a focus on reducing vibrations and improving structural performance. Recently, with the advancements in UAV technologies and additive manufacturing, 3D printing has become an accessible and cost-effective method for rapid prototyping of drone frames. However, compared to traditional material (carbon fiber), 3D printed frames suffer from lower stiff-ness which increases vibrations that negatively affect flight stability, control accuracy, and structural durability. To maximise the viability of 3D UAV frames, this project aimed to increase their performance through improved vibrational behaviour and lightweight designs. The structured approach to this project involved an extensive literature search and the use of CAD models, along with Numerical Modeling Techniques such FEA, Modal Analysis and CFD. The Design of the frames was continuously updated based on the results of the simulations to achieve the best natural frequency and vibration characteristics.According to the results, the vibration characteristics can be impacted by geometrical design. Specifically, the dimensions of the quadcopter’s arms. Increasing the thickness of the arm and decreasing its length increases the first natural frequency. In addition, the results indicated that having holes in the structure reduced stiffness more than it reduced mass, therefore holes were not appropriate as vibration dampening features. However, the implementation of ribs greatly improved the stiffness characteristics and increased natural frequency with very little added weight. As a result of these findings, a set of design recommendations will be developed to assist in optimizing the design of 3D printed UAV frames.The final design fulfilled 12 of the 14 engineering specifications established for this project. The design is a lightweight (640g) frame with a high thrust-to-weight ratio (4:1) and is reasonably strong. This indicates that with proper design considerations, a 3D printed frame can be an acceptable alternative to conventional materials while being accessible, cost-effective and less harmful to the environment. Further work is suggested to improve the efficiency of rib designs and provide experimental validation of simulation results through testing for vibration and testing in actual flight conditions; this project adds to the overall knowledge base of 3D printed UAV design and creates the basis for further advancements in the development of efficient, accessible, and sustainable drone technologies.
Source: American University of Bahrain
Authors: Ali Althawadi, Youssef Farag
Language: English
Subfield: Industrial and Manufacturing Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: green
OpenAlex ID: W7214227141