Solar-Powered UAV Design: Leveraging Minimal Surfaces in Material Extrusion Additive Manufacturing

This paper outlines the methodology employed in the design and production of a fixed-wing aircraft using additive manufacturing techniques, while integrating solar panel technology. A study of the main minimal surfaces has been carried out with the material extrusion process. The results obtained show that it is possible to design and fabricate small UAVs using minimal surface infill as reinforcements with a stiffness to weight ratio equal or superior to conventional materials and processes. Gyroid structures maximize mechanical properties. However, integrating elements like spars and actuators in minimal structures is complex. This study showcases the capability of additive manufacturing in expediting the development of UAVs, resulting in significant reductions in both production costs and time.