SolidWorks-Based Topology Optimization for Octocopter Design and Development

The utilization of Octocopter drones has the potential to extend flight duration and augment load capacity, as the drone's weight and the motors significantly impact these factors. In this study, involves the presentation of a new design, optimization, and development of an Octocopter drone using SOLIDWORKS software. The optimized design was 3D-printed by using polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS). The top cover with 40% weight reduction (35g), base with 25% weight reduction(60g), drone arm with 36% weight reduction (70g), and bracket with 56% weight reduction (10g). The drone frame weigh is 455g in total. The weight, stress, strain, and displacement of the drone parts were determined through simulation. The final design with the best performance among the various designs was chosen using a trade-off analysis. Topology optimization resulted in a 30% weight reduction for all paths. The research explores the design and development of drone controller (Matek Systems F405-VTOL) and electronic speed controller (ESC) Cyclone 20A BLHeli S, including other hardware and software components. As a result, a new approach was developed to reduce the mass of the body structure using topology.