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:
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Topology Optimization based on realistic boundary loads and flat-plate constraints
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Conversion from organic output to prismatic geometry for DFM
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Post-processing for CNC cutability and hardware integration
Results
Tangible Performance and Cost Gains
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40% weight reduction compared to baseline plate
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50% estimated fabrication cost reduction vs AM
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Fully CNC-adapted geometry for flat composite or metal sheet stock
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Load-following internal structure with reduced stress concentrations
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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.
