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Introduction

Drones, also known as Unmanned Aerial Vehicles (UAVs), are


becoming increasingly popular for various applications such as
surveillance, photography, delivery, and scientific research.
The performance and efficiency of a drone largely depend on the
materials used in its construction. This report explores the materials used
in different drone components, focusing on metals, polymers, ceramics,
and composites. The goal is to justify the material selection based on the
relationship between material structure and properties.

Drone Assembly and Component


Analysis

A typical drone assembly consists of several key components, each


requiring specific material properties to function optimally. The main
components include:

i. Frame: Provides structural support.


ii. Propellers: Generate lift and thrust.
iii. Motors: Convert electrical energy into mechanical energy.
iv. Battery: Stores and supplies power.
v. Electronic Speed Controllers (ESCs): Regulate the speed of the
motors.
vi. Camera and Gimbal: Used for capturing images and stabilizing
`footage.
vii. Landing Gear: Provides stability and protection during landing.

Each of these components has different requirements based on their


function within the drone.

Identification of Properties Required for


Drone Applications

Below is a table outlining the properties required for each drone


component:

Component Required Properties


Frame High strength to weight ratio, corrosion resistance,
rigidity
Propellers Lightweight, fatigue resistance, impact resistance
Motors High thermal conductivity, magnetic properties,
mechanical strength
Battery High energy density, lightweight, safety, thermal
stability
ESCs Electrical insulation, thermal conductivity,
durability
Camera and Gimbal Low weight, rigidity, vibration dampening

Landing Gear Impact resistance, lightweight, durability

Materials Used and Their Properties


Component Material Properties
Frame Carbon fibre High tensile
composite strength, low
weight, good
fatigue
resistance
Propellers Polycarbonate or Lightweight,
Nylon high impact
resistance,
good
toughness
Motors Aluminium alloy Good
(e.g., 6061) thermal
conductivity,
corrosion
resistance,
adequate
strength to
weight ratio
Battery Lithium polymer High energy
(LiPo) density, low
weight, high
discharge
rate
ESCs Polymer based Good
PCB materials electrical
insulation,
moderate
thermal
conductivity,
lightweight

Camera Magnesium alloy Low density,


and gimbal good
rigidity,
excellent
vibration
dampening
Landing Glass fiber High impact
Gear reinforced plastic resistance,
lightweight,
good
durability

Structure of Materials Used

Understanding the microstructure of the materials is crucial for


correlating their properties with the specific application requirements:

i. Carbon Fibre Composite: Consists of carbon fibres embedded in a


resin matrix, providing high tensile strength and rigidity due to the
aligned fibre structure.

ii. Polycarbonate/Nylon (Propellers): These are semi-


crystalline polymers with regions of ordered
molecular chains, providing good toughness and
impact resistance.
iii. Aluminium Alloy (Motors): Typically have a face
centred cubic (FCC) crystal structure that offers a good
combination of strength, ductility, and corrosion resistance.

iv. Lithium Polymer (Battery):


Composed of multiple thin layers of
anode, cathode, and separator soaked
in an electrolyte, designed to
maximize energy density and
discharge rates.
v. Polymer based PCB materials (ESCs): These are usually made
from fibreglass reinforced epoxy resin laminates, providing good
electrical insulation and moderate thermal resistance.
vi. Magnesium Alloy (Camera and Gimbal): A hexagonal close-
packed (HCP) structure offers excellent vibration damping and a
good strength-to-weight ratio.

vii. Glass Fibre Reinforced Plastic (Landing Gear): Consists of glass


fibres embedded in a polymer matrix, providing excellent impact
resistance and durability due to the high strength of glass fibres.

Correlation of Structure with Properties

To understand why these materials are selected, we correlate their


microstructure with the required properties:
i. Carbon Fibre Composite (Frame): The aligned carbon fibres
provide high tensile strength and rigidity, ideal for a drone frame
where minimizing weight while maximizing strength is critical.
ii. Polycarbonate/Nylon (Propellers): The semi-crystalline structure
provides excellent toughness and impact resistance, which is
necessary for propellers that undergo repeated stress and possible
collisions.
iii. Aluminium Alloy (Motors): The FCC structure provides good
strength to weight ratio and corrosion resistance, which is
important for motor casings that must dissipate heat efficiently
while remaining light.
iv. Lithium Polymer (Battery): The layered structure maximizes
energy storage while keeping the battery lightweight, crucial for
maintaining long flight times without adding excessive weight.
v. Polymer based PCB materials (ESCs): Fibreglass reinforcement
provides structural stability and thermal resistance, which is
essential for components that regulate high current loads.
vi. Magnesium Alloy (Camera and Gimbal): The HCP structure
allows for excellent vibration damping, crucial for stabilizing the
camera and minimizing vibration induced blurring.
vii. Glass Fibre Reinforced Plastic (Landing Gear): The strong glass
fibres within the polymer matrix provide high impact resistance
and durability, essential for withstanding rough landings.

Justification for Material Selection

The selection of materials for drone components is guided by the need to


balance multiple factors, including weight, strength, durability, and
specific functional properties:
i. Frame (Carbon Fibre Composite): The high strength to weight
ratio is essential to minimize the overall weight while maintaining
structural integrity. The corrosion resistance of carbon composites
also ensures durability in various environmental conditions.
ii. Propellers (Polycarbonate/Nylon): Lightweight and impact
resistant materials are essential for propellers to withstand
rotational stress and possible collisions without deforming or
breaking.
iii. Motors (Aluminium Alloy): Aluminium alloys provide a good
balance between strength and weight while offering excellent
thermal conductivity to dissipate heat generated by the motors.
iv. Battery (Lithium Polymer): LiPo batteries provide high energy
density with a lightweight design, crucial for maximizing flight
time and performance without adding significant weight to the
drone.
v. ESCs (Polymer based PCB materials): Materials that offer good
electrical insulation and moderate thermal conductivity are ideal
for protecting sensitive electronic components from electrical
shorts and overheating.
vi. Camera and Gimbal (Magnesium Alloy): The combination of
lightweight and excellent vibration damping properties makes
magnesium alloys ideal for stabilizing camera equipment, which is
essential for capturing clear and stable images or videos.
vii. Landing Gear (Glass Fibre Reinforced Plastic): The high impact
resistance and durability of glass fibre reinforced plastics provide
reliable protection during landing impacts, reducing the risk of
damage to the drone and its components.
Conclusion

The selection of materials in drone construction is a highly specialized


process that involves balancing various material properties to optimize
performance, durability, and functionality. By correlating the
microstructure of each material with its corresponding properties, we
can understand why specific materials are chosen for each component of
a drone. This ensures that drones are not only lightweight and efficient
but also robust and capable of withstanding various operational stresses.

References

1. Callister, W.D., & Rethwisch, D.G. (2014). Materials Science and


Engineering: An Introduction. Wiley.
2. Ashby, M.F. (2011). Materials Selection in Mechanical Design.
Butterworth-Heinemann.
3. Jones, R.M. (1998). Mechanics of Composite Materials. Taylor &
Francis.
4. Sharma, S.C., & Chawla, K.K. (2006). Composite Materials: Science
and Engineering. Springer.
5. Researchgate.net
6. Wikipedia.org
Made By: -
Name PRN Work
Jayank Patil 123B1G164 Made a final
draft and
helped in
research
Jui Mehendale 123B1G152 Researched
about
structures
Poorva Pathak 123B1G160 Researched
about drone
properties

Sneha Pawar 123B1G166 Researched


about material
and images

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