Client:
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NaviaWorks
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Project:
UAV Platform Development – R&D Program
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​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.​
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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.
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DuroWorks Approach:
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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
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​Results:
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Tangible Performance and Cost Gains
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40% weight reduction compared to baseline plate layout
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50% estimated fabrication cost reduction vs 3D printing
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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
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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.​​​
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Conclusion:
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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.