Towards bio-inspired structural design of a 3D printable, ballistically deployable, multi-rotor UAV

This paper explores bio-inspired design strategies to guide the structural design of a 3D printable, foldable and ballistically deployable, multi-rotor unmanned aerial vehicle (UAV) platform. While folded during transport and launch, the UAV can change its shape in mid-air from a streamlined projectile into a multi-rotor airframe, enabling rapid payload deployment and maneuverability. The UAV design and all-in-one airframe fabrication techniques are described in the context of 3D printing, accommodating multiple moving parts on a platform, which must remain light, streamlined and versatile, fit into a six-inch diameter launch barrel, while capable of withstanding launch accelerations of up to 50g. In order to assess feasibility, analyses were conducted including FEA stress simulations, aerodynamic tests and mechanical prototypes. The latest working model embraces 3D printing, to create a compact, robust and self-contained platform, capitalizing on the ability to design, tune and manufacture complex geometries and fully assembled systems on a small time and cost budget. The UAV's design facilitates deployment under challenging conditions, allowing it to be projectile-launched from the ground or dropped from another aircraft before unfolding at a preset altitude, clear of ground or other obstructions. This capability is particularly useful for applications such as remote exploration and post-disaster relief, where reduced accessibility and the presence of obstructions often complicate swift status assessment.