3D Printed Aircraft Competition: A Framework for Learning Design for Additive Manufacture

Abstract

The annual 3D Printed Aircraft Competition (3DPAC) at the University of Texas at Arlington (UTA) provides a competitive, experiential environment for undergraduate and graduate students to learn and apply design and process knowledge to innovatively design an aircraft with a 3D printed airframe. This paper provides an overview of the competition, case studies of current fixed and rotary wing aircraft designs from UTA design teams, and discussion of key observations and lessons learned from seven years of 3D printed aircraft competitions. In the competition, teams from a range of universities compete in fixed wing and rotary wing categories for prizes in design innovation and flight duration. It challenges students to apply theoretical principles for successful, lightweight vehicle design while considering 3D printing process and material constraints in order to maximize flight performance. Design freedom in terms of size, configuration, weight, and materials allows students to innovate and create to the best of their abilities. Limitations on propulsion duration and flight boundaries require teams to design effective, controllable flight vehicles and configure and size lightweight, efficient structures for maximum flight duration. Design case studies discuss the vehicle and structural design, including loads development, vehicle sizing, structural configuration and sizing, and structural and vehicle testing for aircraft printed using Fused Filament Fabrication (FFF), MultiJet Fusion (MJF), and Continuous Fiber Fabrication (CFF). The discussion emphasizes design considerations for 3D printing limitations such as wall thickness, overhangs and bridging limits, design limits to eliminate the need for supports, process-induced distortion, and printed material integrity.