https://doi.org/10.1051/epjconf/202636701003
Generative design of light weight drone frame using FDM 3d printing – A Review
1 Department of Mechanical Engineering, KPR Institute of Engineering and Technology, Coimbatore, India.
2, 3, 4, 5 Department of Mechanical Engineering, Karpagam College of Engineering, Coimbatore. 641032.
* Corresponding author: This email address is being protected from spambots. You need JavaScript enabled to view it.
Published online: 29 April 2026
Abstract
Endurance versus payload in UAVs is a direct trade-off governed by airframe mass and structural efficiency. Generative design (GD) and topology optimization (TO) are increasingly used to develop lightweight, high-performance drone structures optimized for additive manufacturing (AM). Among AM methods, fused deposition modelling (FDM) is the most cost-effective and accessible for producing polymer frames and substructures. This work reviews GD/TO-based UAV frame design using FDM, including design methods, materials, printing strategies, and validation approaches. Case studies show that incorporating AM constraints during optimization can reduce weight by 20–60% while maintaining or improving stiffness-to-mass ratio. A review of 57+ studies indicates GD can achieve 15–50% mass reduction compared to conventional designs. However, FDM still faces challenges due to anisotropic material behavior and fatigue limitations. Despite increasing demand for low-cost, robust, and lightweight UAV frames, current methods struggle to balance strength and weight effectively. Future work should focus on hybrid composites, multi-objective optimization, and real-world testing to enable reliable and certifiable FDM- based UAV structures.
© The Authors, published by EDP Sciences, 2026
This is an Open Access article distributed under the terms of the Creative Commons Attribution License 4.0, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
