Abstract & Overview
This study details the structural optimization of a 3D-printed plate skid landing gear for fixed-wing unmanned aerial vehicles (UAVs) to improve flight endurance and operational efficiency through weight reduction. The study integrated Topology Optimization (TO) with Additive Manufacturing (AM) techniques, using ANSYS Mechanical for Finite Element Analysis (FEA) and fluid-structure interaction (FSI) simulations to ensure structural integrity under both ground and aerodynamic loads. Topology Optimization revealed the minimal load-bearing regions, enabling targeted material removal while maintaining the exterior airfoil shape. The optimized design achieved a 9.6% weight reduction (from 88.28 g to 79.80 g). Structural performance remained robust: maximum equivalent stress increased negligibly (0.84%), and reduction in factor of safety was minimal. Successfully fabricated using Fused Deposition Modeling (FDM), the new design also reduced production time by 1.89%. This research confirms that the synergy of TO and AM is a viable pathway for developing lighter, more energy-efficient UAV components, and this methodology can be extended to optimize other UAV parts and aerospace structures.