arXiv:2509.09024cs.ROphysics.app-ph2025-09

用连续单丝纤维3D编织技术制造轻量化无人机骨架,强度超金属8倍。

Rapid Manufacturing of Lightweight Drone Frames Using Single-Tow Architected Composites

  • 通过3DFiT技术实现连续单丝纤维精准编织,构建复杂晶格结构。
  • 成品仅重260克,比大疆F450轻10%,特定强度为金属的4至8倍。
  • 适合追求极致轻量与高强度的无人机设计者,可显著延长续航。

航空航天与机器人领域对轻质高强复合材料结构的需求快速增长,尤其在优化无人机机架方面。传统复合材料制造难以实现复杂三维结构以减重,且需拼装部件,导致连接处存在薄弱点。同时,连续纤维增强难以维持,影响结构效率。本研究展示了一种基于面心立方(FFC)晶格结构的无人机机架概念设计,通过3D纤维系留(3DFiT)技术使用连续单丝纤维制造,确保纤维精准对齐,消除传统组装带来的弱点。机械测试表明,所制无人机机架具有约金属和热塑性材料4至8倍的比强度,优于其他常规3D打印方法。该机架仅重260克,比商用DJI F450轻10%,提升结构完整性,使飞行时间延长三分钟,飞行测试证实其在实际工况下的稳定性和耐久性。研究证明了基于单丝晶格桁架的无人机机架具有潜力,3DFiT是一种可扩展、高效的制造方法。

原文摘要 · Abstract (English)

The demand for lightweight and high-strength composite structures is rapidly growing in aerospace and robotics, particularly for optimized drone frames. However, conventional composite manufacturing methods struggle to achieve complex 3D architectures for weight savings and rely on assembling separate components, which introduce weak points at the joints. Additionally, maintaining continuous fiber reinforcement remains challenging, limiting structural efficiency. In this study, we demonstrate the lightweight Face Centered Cubic (FFC) lattice structured conceptualization of drone frames for weight reduction and complex topology fabrication through 3D Fiber Tethering (3DFiT) using continuous single tow fiber ensuring precise fiber alignment, eliminating weak points associated with traditional composite assembly. Mechanical testing demonstrates that the fabricated drone frame exhibits a high specific strength of around four to eight times the metal and thermoplastic, outperforming other conventional 3D printing methods. The drone frame weighs only 260 g, making it 10% lighter than the commercial DJI F450 frame, enhancing structural integrity and contributing to an extended flight time of three minutes, while flight testing confirms its stability and durability under operational conditions. The findings demonstrate the potential of single tow lattice truss-based drone frames, with 3DFiT serving as a scalable and efficient manufacturing method.

无人机复合材料3D编织轻量化

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