Generative design case study of a CNC machined nose landing gear for an unmanned aerial vehicle

Abstract

Generative design is a design method inspired by nature’s evolution, pushing the limits of the industry to new design solutions. Using minimum input requirements, the resulting designs can be structurally adequate, weight-optimised and almost production-ready. The main purpose of this paper is to present the different approaches of the standard engineering design and the generative design methods. This is achieved through the case study of a nose landing gear for a prototype tactical unmanned aerial vehicle, intended for low volume production. The first part of the paper outlines the conceptual design of the nose landing gear. Subsequently, during the preliminary phase, the stress distribution along the different parts is calculated, based on the classic Strength of Materials theory and therefore a design solution is produced. In the second part, a generative design study is carried out with a commercially available tool, based on the conceptual parameters previously chosen. Both concepts are studied with industry-standard finite element analysis tools in order to validate, from a theoretical standpoint, the strength requirements according to the STANAG 4671 regulation. The final structure will be manufactured with 3-axis CNC machining, while providing about 36% weight reduction without compromising the structural functionality.