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FEA Simulation
Custom Drone Frame — Carbon Fiber Optimization
Engineered a high-performance carbon fiber monocoque frame for industrial inspection drones operating in high-wind offshore environments. Integrated finite element modal analysis to ensure resonant frequencies did not overlap with motor RPM harmonics.
CATIA V5ANSYS Composite PrepPostSolidWorks SimulationComposite Layup
3D CAD RENDER // EXPLODED STRUCTURAL VIEW
Engineering Challenge
Excessive frame vibration induced video jello and autopilot IMU sensor noise, limiting max flight velocity to under 45 km/h.
Applied CAD & DFM Solution
Performed multi-layer composite ply orientation optimization (0°/45°/-45°/90° balance) with internal titanium structural inserts at motor mount locations.
Key Modeling & Surfacing Highlights
Parametric surface lofting for aerodynamic arm cross-sections
Interlocking carbon ply alignment slots for foolproof manual layup
Embedded micro-conduits for clean internal wire routing
ENGINEERING SPECIFICATIONS
Material Stack:Toray T800 3K Carbon Fiber Prepreg
Torsional Stiffness:482 Nm/deg
Total Frame Mass:312 grams
First Natural Freq:184 Hz (decoupled from 120Hz motor peak)
Payload Capacity:6.5 kg
THERMAL & STRUCTURAL SIMULATION
Max Stress / Load: 210 MPa (Tsai-Wu composite failure index < 0.35)
Factor of Safety: 4.2
Structure Optimization: 26.5%
Mesh / Analysis Type: Shell 181 Composite Layer Mesh (86,000 elements)
Quantitative Deliverable Results
✓Eliminated sensor noise, allowing flight speed increase up to 88 km/h
✓Flight time extended by 14% due to reduced frame structural weight
✓Crash resistance increased by 2.5x during high-velocity impacts
"The modal tuning Haris engineered into this carbon frame gave our drones unmatched stability in gale-force offshore winds."
Elena Rostova
Lead Systems Architect · SkyeAero Dynamics