[ RETURN TO ALL WORK ]
[ CASE SPECIFICATION // 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
01 // ISOMETRIC 3D CAD RENDER
01 // TECHNICAL CHALLENGE
Excessive frame vibration induced video jello and autopilot IMU sensor noise, limiting max flight velocity to under 45 km/h.
02 // ENGINEERING & DFM SOLUTION
Performed multi-layer composite ply orientation optimization (0°/45°/-45°/90° balance) with internal titanium structural inserts at motor mount locations.
03 // MODELING & TOLERANCING 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
TECHNICAL 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
FEA SIMULATION DATA
Max Stress:210 MPa (Tsai-Wu composite failure index < 0.35)
Safety Factor:4.2
Optimization:26.5%
QUANTITATIVE 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
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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