College of Engineering

Electric and Electronic Engineering Department

Fabricate the pattern design of fixed wing mini uav using 3D printing
technology

Submission of the project as a partial realization of a Bachelor's

Degree

in Aviation Engineering

Submitted By

Jihad Khaled Almoudi

--------------
Supervisor

Ebrahim Alpoishy

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 ACKNOWLEDGEMENTS

It’s a great pleasure to record my sincere gratitude to Supervisor. Ebrahim

Alpoishy for inculcating in me the interest and inspiration to undertake the
project and take it to the completion stage. He has been an excellent guide and a
great source of motivation through all stages of the project. He provided
indispensable encouragement and motivation to me during the progress of
project. He always helped me by regular review of work, supported in resolving
errors and encouraged for future improvements in project. Also His presence
and optimism have provided an invaluable influence on my career. I consider it
my good fortune to have got an opportunity to work with such a wonderful
person, not just professionally but personally as well.
Naturally, completing this in this project would have been a struggle without the
love, sacrifice and support of my parents. My colleagues have also promoted
and supported regularly during the progress of work.

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 ABSTRACT
Unmanned Aerial Vehicles (UAVs) have been developed to perform various military and
civilian applications, such as reconnaissance, attack missions, surveillance of pipelines, and
interplanetary exploration. The present research is motivated by the need to develop a fast
adaptable UAV design technologies for agile, fuel efficient, and flexible structures that are
capable of adapting and operating in any environments. The objective of this research is to
develop adaptive design technologies by investigating current design methods and
knowledge of deployable technologies in the area of engineering design and manufacturing.
More specifically, this research seeks to identify one truss lattice with the optimal elastic
performance for deployable UAV design according to the Hashin & Shtrikman theoretical
bounds. We propose three lattice designs - 3D Kagome structure, 3D pyramidal structure
and the hexagonal diamond structure. The proposed lattice structure designs are fabricated
using SunluT3 3D printer while the material chosen is a called the Polylactic Acid (PLA).

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Table of contents

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CHAPTER 1 INTRODUCTION

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1.1 Introductions
Recent development of UAVS redefined the perspective. Parameters used in UAVS are
range, endurance, altitude and weight. Based on the factors. Weibel et al [9] classified UAVs
in HALE, MALE, mini and micro. Aerodynamic plays an important role in aircraft. The
study is based on various different factors. Ramesh et al[10] identifies various parameters for
both military and civilian UAVs. The author analysed the performance of various UAVs and
categorized them. They also categorized the performance parameters, like range, endurance,
size, maximum take-off weight and operating altitude. The research offers a reasonably
thorough grasp of the criteria that constitute a Mini UAV and its implications for both
military and non-military applications.

1.2 OBJECTIVES OF THE STUDY

 To develop a Mini Unmanned Aerial Vehicle.

 To study the aerodynamic feature of the UAV.

1.3 Scopes and importance of the study to the society

 The UAV can be used in humanitarian effort.
 Mini UAV has agricultural usage potential.
 Mini UAV can be used for surveillance.
 UAV can be used for engineering research purposes.
 UAVs cause less environmental pollution.
 Can be used for building safety inspection.

1.4 Methodology of the research

1. Data Acquisition and Analysis:

Picking an existed UAV design

Analyze the design:

study the wing's features like airfoil shape, thickness variation, leading/trailing edges, and
any internal structures.

2. Material Selection and Printing Setup:

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*Selection of 3D printing material based on the desired characteristics like strength, weight,
and flexibility

*Choosing a suitable 3D printer based on material compatibility and desired resolution

*Optimize printing parameters like layer thickness, infill density, and printing temperature
for strength and weight balance.

3.Printing, Post-Processing, and Testing

1.4 Organization in this project

It consists of five chapters. First is the introduction of the project work. The other four
chapters are:
Chapter Two: Background on Fixed wing UAVs
Chapter Three: 3D printing technology
Chapter Four: Pattern design and 3D printing of the fixed wing uav
Chapter Five: Conclusion
Recommendation for a future work

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Chapter Two: Background of UAV

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2.1 INTRODUCTION
pattern design refers to the specific layout and configuration of the parts within the 3D model
itself. It goes beyond just the overall shape of the drone and focuses on optimizing various
factors for flight performance and functionality.

2.2 Background on Uav Drones

The human’s desire to fly high in the sky emerged as early as its common sense. However, it
took a long time to make this dream real. A large number of scientists had worked on this
topic and it had demanded so many brave people’s life, until finally men could ascend from
the ground. By that, people’s enthusiasm towards the aviation led to success. At first they
conquered the air by balloons, later by airships, and finally with airplanes. Meanwhile, the
idea to use a machine that can fly without a person on board has always been in the
researchers mind. This idea is not surprising at all, because such a system’s advantages are
obvious. We don’t have to count with the death of the on-board personnel, if the aircraft is
destroyed for some reason. In addition, we can use them for such boring tasks, like aerial
reconnaissance. Finally, their financial advantage is unquestionable, due to the fact, that in
general a UAV’s1 price is lower than the price of a conventional aircraft. Similar to a lot of
objects that are used even in the civilian life, UAVs are the results of the developments
carried out during military conflicts. Even though there were some unmanned balloons used
as early as the middle of the 18th century to destroy the enemy, in my papers I examine only
the heavier-than-air UAVs. These type of aircraft appeared in the First World War that’s why
I started to study the history of unmanned aerial vehicles from this date. I divided the history
into four eras, which are separated by the milestones of the development, subsequently by the
military conflicts. As nowadays every nation has their own UAV research program, I found it
important to present some of the Hungarian developments too, in the chapter where I describe
today’s drones2 . Nowadays unmanned aerial vehicles are invaluable assets for each modern
military. We seldom can find a country, whose military does not possess any type of UAV.
So we can say that the history of their development is part of the history of military
technology.

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2.3 CLASSIFICATION OF UAV
UAVs can be found in various shapes and forms depending on their role and missions. Based
on the feature of wing UAV can be found in two types. They are fixed wing and rotary wing
UAV. Rotary wing UAVs use rotor to generate lift and control the direction of paths. Fixed
wing UAVs are a type where the wings generate lift without rotation. It resembles the
structure of traditional aircraft design. The wing or fuselage carry the propulsion system. On
the other hand, the rotary wing is a structure where wing spins to generate lift. These features
can be used in two ways, traditional single rotor with tails or the quadcopter. Recently, the
quadcopters have become very popular. Rotary wing UAV can vertically take-off where the
fixed-wing UAVs need a place to take off. UAVs can be classified on the basis on their
overall weight, payload, range and mission. Most of them are used for military reason.

Figure 1- 1 Sitaria Fixed Wing UAV

Figure 2-1 shows a typical fixed wing UAV which is used in civilian platforms. Sitaria UAV
was developed to perform various tasks of daily life problems. UAV can come in hybrid
format like VTOL, which has characteristics of both fixed and rotary wing UAV. As the
fixed wing UAV need a runway to perform to take off and landing the VTOL UAV has a
good opportunity and sphere of perform. Besides VTOL came in form of a mixture of both
category, which can outperform the rotary wing in case of its performance in many cases.
Another category of fixed wing UAV is flying wing, in which the wing control every aspects
of the UAV. This configuration can reduce the drag generated from an ordinary UAV, thus

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focus more on lift 3 generation and less on control surface. Blended wing design is also
focusing on these kinds of situations. Figure 2-2 shows Desert Hawk, an American military
mini UAV which was deployed for surveillance. This UAV is a popular example of mini
UAV in military application.

Figure 1- 2 Desert Hawk Mini UAV [5]

Table 1- 1 Types of Fixed wing UAVs [8]

Types Typical Range Payload Role Example

High altitude long More than 5000 km Around 1000 kg Military Global Hawk
endurance(HALE)
Medium Altitude Long Around 5000 kms Around 200 kg Military Predator
Endurance
Medium range Tactical Around 250 km Less than 50 kg Military IAI Malat
Close Range Less than 50 Km Less than 10 Kg Military,Civilia Pioneer
n
Mini UAV Less than 20 km Less than 1.5 Kg Military,Civilia Desert Hawk
n
Micro UAV Very Small Very Small Military,Civilia WASP
n

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2.4 OVERVIEW OF MINI UAV
Mini UAV is defined as an unmanned flying vehicle whose overall weight is no more than 10
Kgs. Previously they were designed as hand-launched and controlled via electric medium. As
their size is not suitable for engine system, their propulsion is based on electric motor and
battery. Recent development of electric control systems made them easier to control. A
practical example of these kinds is Lockheed Martin Desert Hawk III, which is used by US
military. It is equipped with advanced battery, modern GPS and other navigation systems and
the weight is not more than 4 kg. It was deployed for tactical surveillance in battlefield like
Iraq. Mini UAVs have smaller range and endurance than that of HALE and MALE UAVs,
but their applications are also different as these are built for smaller ranges. Mini UAVs can
be used for various purposes. It can replace rotor UAVs in some sectors like agriculture and
delivery systems.

2.5 ADVANTAGES OF FIXED WING OVER ROTARY WING

Fixed wing aircrafts have some advantages over rotary wing aircraft. For these reasons fixed
wing UAVs perform better in some cases as they are based on similar principles.
Quadcopters are less operationally effective than fixed-wing vehicles. Longer flying periods,
greater range, and hence more ground covered per mission result from this. Fixed wing
systems have a longer flying time (1–5 hours) than the average quadcopter (15–25 minutes),
which makes them more suitable for missions requiring extended data collection as well as
long-range ISR, search and rescue support and disaster management. Additionally, fixed
wing systems have higher aerodynamic performance and are barely impacted by
environmental factors, enabling them to complete missions in strong winds and being suitable
for usage in a variety of environments. Fixed-wing platforms have a much bigger payload
capacity and can travel further than quadcopters. As a result, the user can transport additional
and larger sensors, twin sensor combinations, and essential supplies for tasks like search and
rescue missions and humanitarian projects, among others. The primary factors that can affect
flying, such as the cruise velocity which can be maintained and regulated using the fixed-
wing UAV. This fact makes it possible to control the shootings accuracy; It is necessary to
post process the images in a way that can significantly alter the final quality of the restitution
because multi-copters UAV typically cannot coordinate the shooting modality with flight
parameters, making it impossible to guarantee images analogous with each other in typology

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and quality[8]. The fixed wing UAV can fly without propeller 5 propulsion (as a glider) this
capability, which is not available for multi-copters drones, ensures a higher level of flight
safety and is further utilized during the shooting moment, the engine is turned down and in
this manner, any potential physical and electromagnetic noises, which may affect the quality
of the taken image are minimized

2.6 Important Parameters for Developing and Classification

UAVs are designed based on various factors. These factors are determined in the design
period. These factors change with the mission profile of the UAVs.

2.6.1 Operating altitude

The altitude above the sea level upto which an aircraft can fly is the operating altitude.
Operating altitude is given in terms of mean sea level reference, while the AGL (above
ground level) flying ability is a factor of the payload and the data link.

2.6.2 Endurance
Endurance means the time an airborne machine fly. Endurance depends on engine type, fuel
etc. Determination of endurance of a Battery operated UAV is different from a fuel. Usually
military UAV needs greater endurance than civilian UAVs.

2.6.3 Operating Range

Operating range means the radial distance which is measured from the ground control station.
Military UAV usually have greater range. On the other hand in civilian application UAVs
have smaller range. In agriculture or traffic control application UAV have limited
application.

2.6.4 Max Take-off Weight

This means the total weight of an aircraft. It consists of payload, battery weight or the fuel, propulsion
system and structural weight.

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2.6.5 Payload
Payloads depends on the mission of a UAV. In civil usage the payload may be a medical
equipment, agricultural products or camera. Payload is determined before the design as it
effects the total weight of an aircraft.

2.6.6 Size
The size of the UAV depends on the payload and total weight. Size means the length of the
fuselage, wing and landing gears.

2.7 HISTORCAL BACKGROUND

In 1903 with the first flight taken by the Wright brothers, developments in aviation
accelerated and soon the first Unmanned Aerial Vehicle was created. It was the time of flying
bombs, which is a manned or unmanned aerial vehicle or aircraft carrying a large explosive
warhead, a precursor to contemporary cruise missiles. In contrast to a bomber aircraft, which
is intended to release bombs and then return to its base for re-use, a flying bomb crashes into
its target and is therefore itself destroyed in its attack. During the First World War it was very
difficult to replace the lost airplanes and pilots, which happened quite frequently due to the
mass introduction of warplanes. To solve this problem, military leaders started to think about
using Unmanned Aircraft, in certain missions. According to the theory of Douhet, a nation’s
resistance could be broken and a country could be defeated by terror bombings. The use of
flying bombs seemed to be a good asset for this task. The first prototype of such a machine
was linked to the American Elmer Sperry, who created an aircraft that was controlled by
autopilot. Military professionals saw big potential in the UAV and they gave seven Curtis N-
9s to be mounted with this autopilot system. First test flights were carried out in 1917 with a
pilot in the cockpit. This pilot was responsible for the take-offs and landings. However, the
other phases of flight were guided by the autopilot. After flying 48 km the bombs were
ejected, but it couldn’t hit closer to the target than 3 km. Another flying bomb, the Kettering
Bug [Figure 2.1] was completed in the November of 1917. It was ordered by the US Military
and constructed by Charles Kettering. The fuselage was created by Orville Wright, the
control and navigation system was developed by the topic’s expert, Elmer Sperry who
created the automatic airplane that was mentioned above. After take-off the small sized,

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biplane was guided by the automatism in the direction of the target, where when the preset
time passed, the engine stopped, the wings fell down. The torpedo shaped body- filled with
80 kg explosive- hit the target and exploded. [13] The 40 HP 4 piston Ford engine could
accelerate the aircraft to 100 km/h. Although the construction was successful, it didn’t
participate in the war, because by the time the U.S. Military put it into service, the war had
ended.

Figure 2- 1 Kettering Bug being prepared for take-off

After the First World War, fighter aircraft became faster, stronger and more maneuverable.
This change affected the method of training of the pilots and the air defense personnel. In
order to simulate how to act against these air targets, Pilotless Target Aircraft or PTA3 s
where developed. A program with the aim of developing such an aircraft ended up in the
creation of the Queen Bee in the United Kingdom. This new type of UAV meant a
breakthrough and was a real innovation. It was the first system with the capability of
returning after completing its mission, unless it was hit. The remote control system was
mounted into a De Havilland DH 82 Tiger Mouth, with a ceiling of 5200 m and a top speed
of 180 km/h. Furthermore the Queen Bee was the first aircraft which was nicknamed Drone,
meaning that it deserves its place in the history books [13]. After the outbreak of the Second
World War, the militaries’ demand for Pilotless Target Vehicles started to grow rapidly.
That’s why the Radio Plane, [Figure 2.2] codenamed OQ-2 was created in the US by
Reginald Denny. It was a monoplane made of wood and propelled by an aircrew. The UAV
could land with the help of a parachute if the datalink was lost for some reason, a function
that proves it to be a relatively developed model. Furthermore it was able to take off from its
landing gears on an ordinary runway. In contrast with the earlier UAVs, damaging could be
avoided because of these features.

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 Figure 2- 2 A Radio Plane on the ramp ready for departure

Following this, several OQ- models were made by Reginald Denny’s company, the most
developed one of this series was the OQ-14, which remained in service even after the Second
World War. During the war, more and more bomber aircraft were lost in the air defense fire
during the terror bombing sorties. The fighting parts started to seek for alternative solutions
to replace the conventional bombers. They returned to the idea of using flying bombs for this
purpose. Germans started to develop the V-1 aerial torpedo in the end of 1930s with the aim
of bombing the city of London. Its technical background was provided by the invention of
pulsejet engine in 1941. The system hadn’t become combat ready for a long time despite
several years of research and experiments. During the test flights is turned out that there were
serious problems with its stability. The V-1 was first used in the combat theatre in 1944
against London, as a revenge for the D-day. The engine provided enough power to take the
warhead, filled with 850 kg explosive, to a distance of 320 km. To control the flight, the
German engineers used a conventional autopilot system consisting of a gyroscope, a
barometric altimeter, and distance measure equipment. After reaching the pre-set distance the
engine stopped, the V-1 became nose heavy, and started to dive, it acted like a bomb
launched from a bomber. At the time of impact, the warhead activated and exploded. During
the Second World War, about 3200 V-1s were launched, which demanded about 1000 life.
This number shows that even though the Germans called it a ‘magic weapon’ it had little
impact on the outcome of the war [15].

2.7.2 EVOLUTION OF AVIATION IN THE FIRST DECADES OF COLD

WAR
After the Second World War, researches related to the UAVs continued, which was
supported by the big development of automatic systems. In the 1950s with the appearance
of aircraft and missiles flying over the speed of sound, the air defense units needed new
assets to simulate targets like these. Military leaders wanted to develop pilotless target
aircraft with supersonic speed. In 1953 the Radioplane branch of Northrop started working
on the AQM-35 supersonic PTA, [Figure 2.3] which carried out its first take-off in 1956. It
was able to fly as fast as Mach 1.55. Its main task was to help with the training of air defense
missile units against supersonic airplanes. Even though it was possible to launch it from the

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ground, most of the cases it was launched from an airplane, from where it was controlled.
All together 25 models was build, but the program was stopped, because the UAV was so
fast that the air defense systems couldn’t track it, so they were unable to lock on this UAV
[13].

Figure 2- 3 The AQM-35 supersonic target PTA

During the cold war, thanks to the global nuclear threat, strategic reconnaissance became
essential. The U-2 spy plane, which was developed by the commission of US government in
the early 1950s, became the symbol of this era. However on 1st May 1960 the Soviet air
defense shot down a U-2 over the Soviet Union. This incident made it obvious, that high
altitude does not provide enough protection, in addition the program’s high costs, and the
media scandal following the shooting down, had shown the disadvantages of such airplanes.
If we take into consideration these factors, it is not surprising that leaders started to think
about unmanned reconnaissance systems that would take high quality photos deep above
the enemy controlled area [6] This is how a new application of UAVs, the reconnaissance
drones were born. In 1960 the USAF gave a commission to the Ryan Aeronautical about
converting the Ryan Model 147 PTAs into reconnaissance drones. This new UAV was given
the name „Lightning Bug” codenamed BQM-34 Firebee. [Figure 2.4] This RPV could be
launched with the help of a catapult either from the ground or from a ship. However, most
often it was started from DC-130 airplanes, which could carry 4 drones at the same time.
Initially, after having finished its mission, the Firebee landed with its parachute, later
specially modified CH-3 helicopter ‘caught’ it, then put it on the ground on a described
location. For the first time, this new unmanned aerial vehicle proved to be a useful asset in
the Vietnam War [13]. During the Vietnam War, these models carried out more than 3400
sorties in the 100th Strategic Reconnaissance Wing. As fighter aircraft were often shot down
by air defense missiles, it became a priority to locate and destroy them. For this purpose the
US used mainly the Firebees. The Vietnamese SA-2 air defense missiles were radio
controlled, so it was easy to detect their omitted signals. The drone sent its reconnaissance
data on a RB-47 airplane, where the location of the missiles was determined on the basis of
this information. In addition the UAV was so developed that it had an active radar warning
receiver, which increased its survival capability. All together the Ryan Aeronautical made 28
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modifications of the Model-147 UAV. The new drones’ tasks included day-and-night
photographing, electronic detection, jamming, deception and spreading leaflets. The fast
reaction was delayed by the fact, that information gathered with this could be analysed
after the UAV’s return. By 1972 it was even possible to broadcast the data live to the ground
station. The Ryan Model 147-SC was equipped with TV camera and datalink system. The
Ryan Model 147N could amplify its radar signals, so it was detected as it was a much larger
target [13]. From 1972 the UAVs joined the propaganda warfare by spreading leaflets,
because the conventional airplanes had suffered serious damage during these missions.

Figure 2- 4. Ryan Model-147 UAV

2.7.3 Ryan Model-147 UAV

In our century stealth capability of fighter aircraft is a basic requirement as well as integrating
the on board system into one complex unit. This idea leads us closer to topic of the
information warfare, whose aim is to achieve information superiority against the enemy. In
the information warfare, both the soldier and the commanding post have a huge need of
constant information. To meet this demand, UAVs are used in mass, and they are
indispensable in the flow of information. Due to their effectiveness their number is still
growing. Although their main purpose was gathering information, today they can execute air
interdiction or air suppression missions [4]. Air strike capability is best represented by the
MQ-9 Reaper UAV [Figure 2.5] of the United States. The Reaper is the big brother of the
Predator, which flew in 2001 for the first time. It is the first hunter-killer UAV designed for
long-endurance, high-altitude surveillance. However, its main task is to strike ground targets.
For this purpose it can be mounted with several suspension equipment, like the AGM-114
Hellfire air-to-ground missile, GBU-12 laser or GBU-38 JDAM satellite guided bomb.
Besides airstrikes, it can carry out strategic air surveillance too, due to its 14-42 hours of
endurance. Its first sortie was in Afghanistan in 2007, but since that it was also used in the
conflicts of Libya and Mali. The Predator and Reaper aircraft have the highest operational
readiness rate of any aircraft in the US DoD inventory, often exceeding 99% mission
availability rate. In today’s asymmetric warfare the small, cheap, hand-launched UAVs
became extremely important, especially at the army and the marines. They can be used in the
urban warfare too, because they are powered by electricity, which makes them silent,

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portable, and can be controlled with the help of a laptop or tablet. These drones are usually
mounted with EO or IR cameras, and its pictures are transmitted in real time to the operator.
However we have to take into consideration that in their operational altitude the possibility of
visual coordination goes sour due the circumstances of the combat theatre, like smoke, dust
or fire. The Black Hornet Nano [Figure 2.5] is the best example for this type of drones. This
is a military micro unmanned aerial vehicle developed by Prox Dynamics AS of Norway, and
in use by the Norwegian and British Army and US Marine Corps. The unit measures around
10×2.5 cm and provides troops on the ground with local situational awareness. They are
small enough to fit in one hand and weigh just over 16 g, including batteries. An operator can
be trained to operate the Black Hornet in as little as 20 minutes. The UAV is equipped with a
camera, which gives the operator fullmotion video and still images.

Figure 2- 5 A British Reaper operating over Afghanistan in 2009 and a Black Hornet Nano

This article would not be complete without briefly mentioning the Hungarian UAV
developments and researches. The Meteor PTA family has been produced for Hungarian
Defense Forces since 1999 by the Aero-Target Bt. These UAVs are used mainly to train the
air defense units’ personnel, on the practice missile shootings. The first product was the
Meteor-1 in the series. In 2005 the company won the competition to modernize the existing
PTAs. The Meteor3 [figure 2.6] made it possible to provide cheap and fully Hungarian target
material for the users. This UAV is able to follow a rout automatically. Even though its top
speed is only 140 km/h, its duration is 40 minutes and range is 60 km. The Meteor-3 has a
payload of 4 kg including fuel, and ceiling of 3000 m. It can carry up to 4 pyrotechnic
cartridges, but can be mounted with radio telemetry too. In addition it can transport a 180 mm
Luneberg lens to increase its radar cross section. The 2.7 m wingspan, 1.8 m long and 11kg
body is powered by a 30 cm3 piston engine. It is launched with the help of catapult and it
lands on its skids. Unfortunately, its slow speed decreases its credibility, so the producer
began developing a faster PTA.

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 Figure 2- 6 . the Meteor-3 ready for departure and an airborne Skylark

Probably, the most important reconnaissance UAV of the Hungarian Defense Forces is the
Skylark I LE [Figure 2.6], which was bought from Israel in 2009. In this year the training of
the per- sonnel could be started too, both in Hungary and Israel. After the training the system
was deployed to the PRT4 shift in Afghanistan. During the time it spent on mission, it
gradually fitted into the system of the team. As the number of flights and the flying hours
grew, the demand for the real time air surveillance was growing too. The live pictures were
broadcasted to the operational center, giving a huge help for the decision makers. It was used
in FOB5 missions and to secure CIMIC6 projects. The UAV was also useful in detecting a
possible IED7 attack. Besides these route surveillance in front of own forces, and convoy
escort became its principal tasks too. In our century, we can see that UAVs are used in more
and more fields. As they are getting more developed, they can replace conventional aviation
in larger and larger numbers. By this, I mean that we have seen that conventionally drones
are used for four main purposes:  a weapon system where the aircraft itself is the weapon
(flying bomb);  or it is mounted with some kind of weapons (Reaper);  information
gathering unit including all UAVs with cameras and reconnaissance equipment (Predator); 
as a simulated target for the air defense units (PTA). However, today there are researches to
create cargo unmanned aerial vehicles too for example the Eurocopter EC-145. This fact
suggests that the potential using of UAVs is seemingly unlimited, because of the constant
growing of applications and it has become obvious for all militaries in the world. Therefore
every nation has its researches in this topic, including countries with such a small military,
like Hungary. As time passes they will get so advanced, that we can start thinking about,
when will they replace conventional aviation, or will they ever replace it completely? [16]
[17][18]

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Chapter Three: 3D Printing Technology

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3.1 Introduction
3D printing (3DP) refers to an innovative digital fabrication process that enables
manufacturing of physical parts by building thin layers upon layers based as per the input
provided by the digital design. 3DP realizes fabrication of even complex geometries without
using geometry-specific tools or fixtures. As the integration of 3DP with product
development process leads to substantial time compression, several engineering sectors
deploy 3DP in numerous stages of product development from conceptualization to
production. The published literature that delineates the use of 3D printed plastic parts in the
development of MAV is scarce.

During the initial evolution phase of 3DP technology, it was referred by alternate names such
as rapid prototyping, solid freeform fabrication and layered manufacturing. In recent years,
the terminology of additive manufacturing has gained universal acceptance in recognition of
the fact that 3DP parts are realized through addition of material rather than subtraction which
is a typical of conventional manufacturing. Stereolithography (SL), fused deposition
modeling (FDM), laser sintering and polyjet technology are the popularly used 3DP
processes for fabricating precision plastic parts. The initial applications of these various 3DP
options were limited to form and fitment applications rather than functional demands due to
limited materials and poor geometrical accuracy. However, recent applications of 3DP
processes have showcased versatility and much greater impact on entire product development
cycle. Especially in case of MAV applications wherein number of parts or systems that need
to be fabricated is limited to a few, the engineering teams need a process that can transform
design concepts into physical parts in the quickest turnaround time without imposing
restrictions related to geometry, tooling and cost.

3.2 Materials Used for 3D Printing Technology in Manufacturing Industry:

1. Metals: Metal 3D printing technology gain many attentions in aerospace, automobile,
medical application and manufacturing industry because the advantages existing by
this process The materials of metal have the excellent physical properties and this
material can be used to complex manufacturer from printing human organs to
aerospace parts.

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2. Polymers: 3D printing technologies are widely used for the production of polymer
components from prototypes to functional structures with difficult geometries By
using fused deposition modelling (FDM), it can form a 3D printed through the
deposition of successive layers of extruded thermoplastic filament, such as polylactic
acid (PLA), acrylonitrile butadiene styrene (ABS), polypropylene (PP) or
polyethylene (PE)
3. Ceramics: Nowadays, 3D printing technology can produce 3D printed object by using
ceramics and concrete without large pores or any cracks through optimization of the
parameters and setup the good mechanical properties . Ceramic is strong, durable and
fire resistant. Due to its fluid state before setting, ceramics can be applied in
practically any geometry and shape and very suitable on the creation of future
construction and building
4. Composites: Composite materials with the exceptional versatility, low weight, and
tailorable properties have been revolutionizing high-performance industries. The
examples of composite materials are carbon fibers reinforced polymer composites and
glass fibers reinforced polymer composite Carbon fiber reinforced polymers
composite structures are widely used in aerospace industry because of their high
specific stiffness, strength, good corrosion resistance and good fatigue performance

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Figure 3- 1 3D printing Materials

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3.3 advantages and disadvantages of 3d printing technology
 Advantages

1. Design Freedom: Unlike traditional manufacturing methods limited by tools and

materials, 3D printing allows for the creation of complex and intricate designs. This
opens doors for innovative products and functional prototypes.

2. Rapid Prototyping: Gone are the days of lengthy and expensive prototyping
processes. 3D printing enables designers to quickly iterate and test designs,
accelerating product development cycles.

3. Reduced Waste: Traditional manufacturing often generates significant scrap

material. 3D printing uses only the required material for each layer, minimizing waste
and promoting sustainability.

4. On-Demand Manufacturing: This technology empowers businesses to produce

parts and products locally, reducing reliance on large-scale manufacturing and
enabling just-in-time production.

5. Lightweight Parts: 3D printing allows for the creation of lightweight yet strong
structures, making it valuable in industries like aerospace and automotive where
weight reduction is crucial.

 Disadvantages

1. Cost: While the cost of 3D printers is decreasing, they can still be expensive,
especially for high-quality machines. Additionally, certain materials used in 3D
printing can be quite pricey.

2. Print Time: The printing process can be slow, particularly for large or complex
objects. This can be a drawback for projects requiring rapid production.

3. Limited Material Selection: While the range of materials available for 3D printing is
expanding, it still doesn't match the vast selection used in traditional manufacturing.

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 4. Strength Concerns: The strength and durability of 3D printed parts can vary
depending on the material and printing process. They may not always be suitable for
high-stress applications.

5. Post-Processing: Some 3D printed objects require additional processing like

cleaning, smoothing, or assembly, adding extra time and effort to the process.

6. Skill Requirement: Operating a 3D printer effectively often requires some technical

knowledge and experience, especially for complex projects.

3.3.1 (3D) Printer data collection

There are major of 3d printers available in the market Like :

1- The Bambu Lab X1-Carbon which is high-end 3D printer that has garnered
significant attention in the maker community for its impressive speed, print quality,
and innovative features. Positioned as a direct competitor to other premium 3D
printers

Figure 3- 2 Bambu Lab X1-Carbon

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Feature of the printer

 High-Speed Printing
 Superior Print Quality
 wide range of Material Compatibility
 Reliability and Durability
 High price tag of
2- The Creality K1 is a consumer-grade 3D printer that aims to bridge the gap between
hobbyist and professional-grade machines. It's positioned as a user-friendly option
with a focus on print quality and reliability. Featuring a sleek design and a range of
advanced features, the K1 targets both beginners and experienced users

Figure 3- 3 Creality K1

Features of the printer

 Large Build Volume
 User-Friendly Interface
 User-Friendly Interface
 Good range of material compatibility

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  Medium price tag of
3- The Sunlu T3, often referred to as the Terminator 3, is a mid-range 3D printer that has
gained popularity due to its combination of affordability and features. It’s positioned
as a user-friendly option for both hobbyists and small-scale production.
Features of the printer
 Descent print quality.
 Quiet Operation.
 Good range of Filament Compatibility.
 Affordable Price.

Sunlu T3 primarily relies on third-party slicing software for its operations. While the printer
itself comes with basic controls, the intricate process of converting 3D models into printable
G-code instructions requires specialized software.

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Cura: A widely used, open-source slicer with a vast community and extensive support. It
offers various features, customization options, and profiles for different printers, including
the Sunlu T3.

After enough information about the printers it’s been concluded that The Sunlu T3 is the
most affordable printer in Libya .

3.3.2 Software overview

UltiMaker Cura is free , easy-to-use 3D printing software installed from the original site of
Ultimaker

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Chapter Four: Pattern Design And 3D Printing of
The Fixed Wing Uav

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4.1 Introduction
A comprehensive analysis of existing UAV models was conducted to identify key
specifications relevant to this research. Factors considered included aircraft weight, power
source, takeoff and landing methods, operational altitude, and payload capacity. Based on
this analysis, the following UAV characteristics were deemed essential: a maximum
operating altitude of 300 meters, a weight below 4.5 kilograms, hand launch capability, belly
landing, fixed camera mounting, and an electric motor powered by a battery.
UAV selection was based on:

 Portability and Ease of Use

 Affordability
 Maneuverability and Access
 Safety
 Regulations

Based on the past factors these 2 UAVs was picked as shown in figures(4-1),(4-2)

Figure 4- 1 The first uav model

Figure 4- 2 the second uav model

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The table (4-1) below shows the first model specifications

Table 4- 1 The First model specifications

Wingspan 2224mm

wingarea 3783cm2

Body length

MTOW 4.5kg

Root chord 220mm

Tip chord 124mm

Average chord 172mm

And the table (4-2) below shows the Second model specifications

Table 4- 2 The Second model specifications

Wingspan 900mm

wingarea 1136cm2

Body length

MTOW 1.7kg

Root chord 150mm

Tip chord 61mm

Average chord 111mm

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