Client
​
NaviaWorks
​​
Project
​UAV Platform Development – R&D Program
​
​Objective
Design a lightweight, flat-plate frame for a tilting-rotor FPV quadrotor drone, suitable for waterjet/laser cutting or CNC routing using carbon-epoxy or aluminum sheets. The aim: reduce structural weight and fabrication cost, while preserving stiffness and manufacturability.​​​
​
Baseline Challenge
​
The drone’s innovative tilting-rotor architecture included a frame loaded by rotating propulsion arms and roller-mounted components, introducing complex load paths from thrust and inertial forces. The baseline solution consisted of a simple but inefficient stacked plate configuration.
​
DuroWorks Approach
We applied a customized GD workflow:
-
Topology Optimization based on realistic boundary loads and flat-plate constraints
-
Conversion from organic output to prismatic geometry for DFM
-
Post-processing for CNC cutability and hardware integration​
​​​
​​​Results
​
Tangible Performance and Cost Gains
​
-
40% weight reduction compared to baseline plate
-
50% estimated fabrication cost reduction vs AM
-
Fully CNC-adapted geometry for flat composite or metal sheet stock
-
Load-following internal structure with reduced stress concentrations
-
Repeatable process for other drone platforms or small vehicles
​​
Key Innovation
​​Unlike traditional GD approaches focused only on Additive Manufacturing, the DuroWorks method delivers near-final geometries optimized for real-world production. This approach unlocks the benefits of GD while keeping fabrication simple, scalable, and affordable.​​​
​​
Conclusion
​
This drone frame project proves that GD and Structural Optimization can deliver concrete value even in compact, cost-sensitive systems. DuroWorks offers a flexible, hybrid approach that enhances performance and manufacturability without increasing risk or complexity. Ideal for UAV platforms, consumer robotics, and advanced prototyping environments.
