Fused Deposition Modeling Technique Research Articles

3D-Printed Electrochemical Sensors: A Comprehensive Review of Clinical Analysis Applications

Three-dimensional printing technology has emerged as a versatile and cost-effective alternative for the fabrication of electrochemical sensors. To enhance sensor sensitivity and biocompatibility, a diverse range of biocompatible and conductive materials can be employed in these devices. This allows these sensors to be modified to detect a wide range of analytes in various fields. 3D-printed electrochemical sensors have the potential to play a pivotal role in personalized medicine by enabling the real-time monitoring of metabolite and biomarker levels. These data can be used to personalize treatment strategies and optimize patient outcomes. The portability and low-cost nature of 3D-printed electrochemical sensors make them suitable for point-of-care (POC) diagnostics. These tests enable rapid and decentralized analyses, aiding in diagnosis and treatment decisions in resource-limited settings. Among the techniques widely reported in the literature for 3D printing, the fused deposition modeling (FDM) technique is the most commonly used for the development of electrochemical devices due to the easy accessibility of equipment and materials. Focusing on the FDM technique, this review explores the critical factors influencing the fabrication of electrochemical sensors and discusses potential applications in clinical analysis, while acknowledging the challenges that need to be overcome for its effective adoption.

Extrusion-Based Three-Dimensional Printing of Metronidazole Immediate Release Tablets: Impact of Processing Parameters and in Vitro Evaluation

PurposeThe current study assessed the potential of a pneumatic 3D printer in developing a taste-masked tablet in a single step. Metronidazole (MTZ) was chosen as the model drug, and Eudragit® E PO was used as a taste-masking polymer to produce taste-masked tablets.MethodsThe study focused on optimizing processing parameters, such as the nozzle's printing speed, the printhead's heating temperature, and the pressure. Oval-shaped tablets were printed with a rectilinear printing pattern of 30% and 100% infill and evaluated for in vitro drug release and taste masking. The 3D-printed tablets are also characterized using Differential Scanning Calorimetry (DSC), Fourier-transform Infrared Spectroscopy (FTIR), and Scanning Electron Microscopy (SEM).ResultsThe infill density impacts the drug release profile of the tablets. F9, F10, and F11 displayed desired printability among the formulations, with F9 and F10 exhibiting over 85% drug release within 60 min in the in vitro dissolution study. The F9 formulation, with 30% infill, effectively masked the bitter taste of MTZ in the in vitro dissolution study carried out in a pH 6.8 artificial salivary medium. The observed release was below the tasting threshold concentration of the model drug.ConclusionIn summary, 3-dimensional extrusion-based printing combines the effects of hot-melt extrusion and fused deposition modeling techniques in a single-step process, demonstrating potential as an alternative to the fused-deposition model 3D printing technique and warranting further exploration.Graphical

Analysis of 3D Printed Dielectric Resonator Antenna Arrays for Millimeter-Wave 5G Applications

This paper explores the potential use of fused deposition modeling (FDM) technology for manufacturing microwave and millimeter-wave dielectric resonator antennas (DRAs) for 5G and beyond communication systems. DRAs operating at microwave and millimeter-wave (mmWave) frequency bands were simulated, fabricated, and analyzed in terms of manufacturing quality and radio frequency (RF) performance. Samples were manufactured using a 3D printer and PREPERM® ABS1000 filament, which offers a stable dielectric constant (εr = 10 ± 0.35) and low losses (tan δ = 0.003) over wide frequency and temperature ranges. Surface profile tests and microscope measurements revealed discrepancies in the dimensions in the xy-plane and along the z-axis, consistent with the observed shift in resonant frequency. Despite these variations, reasonably good agreement between RF-simulated and measured results was achieved, and the DRA array successfully covered the intended mmWave band. However, challenges in achieving high precision may restrict applications at higher mmWave bands. Nevertheless, compared with conventional methods, FDM techniques offer a highly accessible and flexible solution with a wide range of materials for home and micro-manufacturing of mmWave DRAs for modern 5G systems.

Analysis of Geometrical Accuracy and Surface Quality of Threaded and Spline Connections Manufactured Using MEX, MJ and VAT Additive Technologies.

This paper presents the process of manufacturing mechanical joint components using additive manufacturing (AM) techniques such as Material Extrusion (Fused Deposition Modelling (FDM)), Material Jetting (PolyJet), and Vat Photopolymerization (VAT)/Stereolithography (SLA). Using the PolyJet technique and a photopolymer resin, spline and threaded joint components were produced. For comparative analysis, the threaded joint was also fabricated using FDM and SLA techniques. PLA material was used for the FDM technique, while photopolymer resin was utilized for the SLA process. The components produced underwent a surface analysis to evaluate the accuracy of the dimensions in relation to the nominal dimensions. For the spline connection components, the dimensional deviations recorded by a 3D scanner ranged from -0.11 to +0.18 mm for the shaft and up to 0.24 mm for the sleeve. Measurements of screw and nut diameters showed the highest accuracy for screws produced using the PolyJet technique, while the nuts exhibited the best accuracy when fabricated with the SLA method. The profile of the screw threads using a contour gauge revealed the most accurate thread profile on the screw manufactured with the PolyJet technique.

Particularities on the Low-Velocity Impact Behavior of 3D-Printed Sandwich Panels with Re-Entrant and Honeycomb Core Topologies

This work describes, through experimental and numerical investigations, the mechanical behavior and energy absorption characteristics of 3D-printed sandwich panels with cellular cores subjected to low-velocity impact. Using fused deposition modeling techniques (FDM), three different sandwich panels, one with a regular hexagonal core and two with re-entrant cores at 0 and 90 degrees, were fabricated. The sandwich panels were subjected to low-velocity impact, at impact energies of 10 J and 15 J. A comprehensive investigation of the panels’ behavior through experimental testing and numerical simulation was conducted. The results indicate that the sandwich panel with a 90 degrees re-entrant core is stiffer and absorbs the largest amount of impact energy but, at the same time, suffers significant damage to the upper facesheet. The 0 degrees re-entrant core is compliant and provides both impact resistance and good energy absorption characteristics. Such a sandwich panel finds its application in the construction of personal protective equipment, where the aim is to minimize the forces transmitted during low-velocity impacts and maximize the total absorbed energy. Re-entrant core sandwich panels prove to be very good candidates for replacing the honeycomb core sandwich, depending on the desired engineering application.

The Influence of Printing Speed and Temperature on the Mechanical, Absorptive, and Morphological Properties of PLA-Based Hybrid Materials Produced with an FDM-Type 3D Printer.

Composite materials are used in many engineering applications and industrial fields due to their superior properties, such as high strength, lightweight, and stiffness. These outstanding properties have made these materials an alternative to metallic materials. The vital need for new lightweight and inexpensive materials with superior strength properties has led to research on "hybridisation". Hybrid composites with more than one type of polymer in the same structure are needed to achieve a better balance of properties and to combine many desired properties in a single material. Many researchers have studied the hybrid effect and contributed to the understanding and modelling of the subject. Studies to explain the primary mechanism of the hybrid effect are limited and insufficient to explain the complex interaction. In this study, a three-dimensional printer using fused deposition modelling technique was used to produce hybrid materials, and the influence of printing parameters on the mechanical, absorptive, and morphological properties of poly (lactic acid) (PLA), Tough PLA, and PLA/Tough PLA hybrid materials were investigated. The hybrid material form exhibited superior properties when selecting specific production parameters from individual raw elements. It can be said that the mechanical properties of the PLA/Tough PLA hybrid material increased with the increase in production temperature.

Tensile fracture prediction of 3D-printed V-notched PLA specimens: Application of VIMC-MEMC in conjunction with brittle fracture criteria

This study investigates the fracture behavior of additively manufactured round-tip V-notched diagonally loaded square plate (RV-DLSP) specimens with different notch opening angles and tip radii produced from the Polylactic acid (PLA) with [0/90/45/-45]s raster orientation using the fused deposition modeling (FDM) technique. PLA is known for its ductile behavior, making it a suitable material for various engineering applications. Also, the layer-wise manufacturing process in FDM technique makes the PLA specimens be actually anisotropic. To take the nonlinearity and anisotropy of PLA simultaneously into consideration in prediction of the fracture loads of RV-DLSP specimens, the present study employs the Virtual Isotropic Material Concept (VIMC) and modified Equivalent Material Concept (MEMC) in a two-level strategy of simplifying PLA to an isotropic linear elastic virtual material. Then, the mean stress (MS) and maximum tangential stress (MTS) criteria are utilized to estimate the fracture loads. The theoretical estimations reveal that the VIMC-MEMC-RV-MS criterion is the most accurate model, demonstrating its effectiveness in predicting the fracture behavior of RV-DLSP specimens. Additionally, the VIMC-MEMC-RV-MTS criterion shows commendable accuracy, particularly for the specimens with 30 (deg.) notch opening angle. The scanning electron microscopy (SEM) analysis of the fracture surfaces provides further insights into the fracture mechanisms of RV-DLSP specimens. Notably, distinct fracture patterns are observed based on variations in the notch geometry. Specimens with smaller notch tip radii exhibit fiber cleavage, while those with larger radii display greater fiber interpenetration. These SEM observations are consistent with the fracture load data, which indicates higher fracture loads with increasing the notch opening angle and tip radius. By integrating VIMC and MEMC with the two fracture criteria, accurate predictions of the notch fracture toughness can be achieved, facilitating the design and optimization of 3D-printed PLA components against fracture.

Investigation of compressive strength of primitive geometries printed through the fused deposition modeling technique with different path patterns

Fused Deposition Modeling (FDM) is a material-extrusion-based technique used primarily for rapid prototyping and sometimes for an actual servicing part. In the FDM technique, input parent materials are commercial polymers. FDM also has some manufacturing parameters, and the raster pattern significantly affects the mechanical performance of the FDM products. Due to its intrinsic nature, Acrylonitrile Butadiene Styrene (ABS) is widely used in many industries, such as automobiles, medicine, etc. Producing the primitive geometry and selecting the proper infill pattern is challenging. Therefore, the current research paper investigates the effects of various infill patterns on the compressive performance of the three geometries (sphere, 3-side, and 4-side pyramids) printed through the FDM technique out of ABS material. The compressive experiments were conducted on the printed samples and load-displacement curves were evaluated. The results reveal that the concentrate path pattern in the sphere samples has the highest compressive failure load (40127 N). Also, the compressive failure loads in the 3-side and 4-side pyramids fabricated with a 45°/−45° raster pattern are 30444 N and 44396 N, respectively. Finally, comprehensive discussions about the obtained results are stated.

On multi-stage deformation and gradual energy absorption of 3D printed multi-cell tubes with varying cross-section

Thin-walled structures are widely used in passive safety systems due to their excellent lightweight and controllable progressive deformation performance. While designing to improve the energy absorption performance of thin-walled structures, it is also crucial to consider reducing the damage received by protected objects during accidental collisions. In this work, stepwise and continuous graded multi-cell tubes with varying cross-sections were proposed based on the fused deposition modeling technique to achieve a gradual energy absorption process. Compression responses and energy absorption characteristics of the graded multi-cell tubes were investigated by quasi-static compression tests. Experimental results showed that the stepwise graded multi-cell tubes produced obvious multi-stage deformation and energy absorption during axial compression. The specific energy absorption presented an upward trend with the increased number of stepwise segments. For the same ranges of cross-section variations, continuous graded multi-cell tubes exhibited more plastic hinges and better energy absorption performance due to the absence of discontinuous interfaces. In addition, continuous graded multi-cell tubes showed continuous folding deformation with the gradually decreasing folding wavelength. Thus, it exhibited a steadily increasing trend in crushing force and realized the gradual energy absorption mode.

Development of isotactic polypropylene‐based 3D printing materials with good dimensional accuracy and excellent impact properties

AbstractThe main challenge of fused deposition modeling (FDM) is the limited variety of commercially available semicrystalline polymer materials. Isotactic polypropylene (iPP), with a fast crystallization rate and high crystallinity, tends to undergo extensive volumetric shrinkage during the FDM process, further inducing severe deformation and poor dimensional accuracy in 3D‐printed parts. This study aims to develop desirable iPP‐based materials for the FDM technique through physically blending iPP and thermoplastic polyester elastomer (TPEE). TPEE retards the nonisothermal crystallization ability of iPP, as indicated by the significant decrease in crystallinity (Xc) from 47.7% for neat iPP to 28.5% for the iPP blend at a weight ratio of 30/70. The suppressed crystallization behavior accounts for a drastic decrease in the warpage degree of the 3D‐printed parts. The greater the content of TPEE is, the lower warpage the 3D‐printed parts have. Additionally, the presence of TPEE slightly influences the shear viscosity of iPP. As a result, iPP blends exhibit excellent extrudability during a typical FDM process. TPEE also enhances the impact strength of 3D‐printed parts by 168% compared to that of injection‐molded iPP. Taken together, the iPP blends developed in this work are promising FDM feedstock materials with good dimensional accuracy and excellent impact strength.

Comprehensive Evaluation of Printing Process Parameters and Tensile Properties of Coconut Polypropylene Filament Composites in Additive Manufacturing

The printing process parameters are important in producing coconut polypropylene (CcPP) products by filament composite in the additive manufacturing industry. Fused deposition modeling techniques in 3D printing applications have considered multiple parameters to meet good finishing parts. This study uses comprehensive measurements to identify the best printing parameter for evaluating the composite properties. Complete deposition, unwrapping, good finishing, and adequate heat are the qualitative printing process parameters used to finalize the optimum nozzle and bed temperature of the CcPP filament composite. The range between 50⁰C to 80⁰C and 225⁰C to 245⁰C for bed and nozzle temperatures were used to achieve a well surface and successful production. After multiple trials of printing the CcPP filament composite, the optimal bed and nozzle temperatures were found to be 80°C and 230°C, respectively. Two types of infill density were used to analyze the effect on the tensile properties of CcPP filament composite. The result showed that 50% infill density was higher for both 1% and 5% fiber loading than 25% infill density for tensile strength with 15.65 and 22.87 MPa compared to 12.93 and 16.59 MPa. The same pattern as the score of Young’s moduli of 50% infill density was higher than 25% infill density for 1% and 5% fiber loadings with 479.52 and 641.23 MPa compared to 400.17 and 493 MPa. Qualitative and quantitative measurements of printing process parameters and properties help reduce the time and cost and benefit 3D printer users in the industry.

Self-assembled monolayers of reduced graphene oxide for robust 3D-printed supercapacitors

Herein, additive manufacturing, which is extremely promising in different sectors, has been adopted in the electrical energy storage field to fabricate efficient materials for supercapacitor applications. In particular, Al2O3-, steel-, and Cu-based microparticles have been used for the realization of 3D self-assembling materials covered with reduced graphene oxide to be processed through additive manufacturing. Functionalization of the particles with amino groups and a subsequent "self-assembly" step with graphene oxide, which was contextually partially reduced to rGO, was carried out. To further improve the electrical conductivity and AM processability, the composites were coated with a polyaniline-dodecylbenzene sulfonic acid complex and further blended with PLA. Afterward, they were extruded in the form of filaments, printed through the fused deposition modeling technique, and assembled into symmetrical solid-state devices. Electrochemical tests showed a maximum mass capacitance of 163 F/g, a maximum energy density of 15 Wh/Kg at 10 A/g, as well as good durability (85% capacitance retention within 5000 cycles) proving the effectiveness of the preparation and the efficiency of the as-manufactured composites.

Effect of printing parameters on impact energy absorption of additively manufactured hierarchical structures

PurposeThis study aims to examine how the thickness of layers and printing speed impact the energy absorption capacity of honeycomb structures through drop-weight experiments. In addition, the effect of printing orientation on the resulting microstructure and mechanical performance was targeted to be examined.Design/methodology/approachIn this paper, after manufacturing test specimens using fused deposition modeling technique with three distinct layer thicknesses (0.16 mm, 0.20 mm and 0.28 mm) and printing speeds (40 mm/min, 50 mm/min and 70 mm/min), drop weight tests were carried out. Then to see the effect of printing orientation on mechanical performance, three-point-bending tests were performed and damage mechanisms were comparatively examined through scanning electron microscopy.FindingsAn increase in layer thickness from 0.16 mm to 0.28 mm resulted in a notable 37% decrease in the impact resistance of the printed part. In addition, increasing the printing speed from 50 to 70 mm/min reduced the energy absorption capacity of the printed part by approximately 36.5%. Moreover, in terms of printing direction, transversely printed specimens showed 10% lower flexural strength than longitudinally printed specimens. Finally, scanning electron microscopy (SEM) observation showed that internal defects were more prominent in transversely printed specimens, resulting in premature failure. Furthermore, delamination was also detected in transversely printed specimens as another damage mechanism accelerating material failure.Originality/valueIt is seen that the effect of printing parameters on the fundamental mechanical properties including tensile strength, strain at break, ductility and elastic modulus were studied by various researchers. However, to the best of authors’ knowledge, the effect of printing speed and layer thickness on the energy absorption of polylactic acid based hexagonal honeycomb was not encountered. In addition, in-depth SEM analysis to discover the influence of printing direction significantly contributes to the literature.

Bioinspired poly-dopamine/nano-hydroxyapatite: an upgrading biocompatible coat for 3D-printed polylactic acid scaffold for bone regeneration.

Poly-lactic acid (PLA) has been proposed in dentistry for several regenerative procedures owing to its biocompatibility and biodegradability. However, the presence of methyl groups renders PLA hydrophobic, making the surface less ideal for cell attachment, and it does not promote tissue regeneration. Upgrading PLA with inductive biomaterial is a crucial step to increase the bioactivity of the PLA and allow cellular adhesion. Our purpose is to evaluate biocompatibility, bioactivity, cellular adhesion, and mechanical properties of 3D-printed PLA scaffold coated with poly-dopamine (PDA) and nano-hydroxyapatite (n-HA) versus PLA and PLA/n-HA scaffolds. The fused deposition modelling technique was used to print PLA, PLA with embedded n-HA particles, and PLA scaffold coated with PDA/n-HA by immersion. After matrices characterization for their chemical composition and surface properties, testing the compressive strength was pursued using a universal testing machine. The bioactivity of scaffolds was evaluated by monitoring the formation of calcium phosphate compounds after simulated body fluid immersion. The PLA/PDA/n-HA scaffold showed the highest compressive strength which was 29.11 ± 7.58 MPa with enhancing calcium phosphate crystals deposition with a specific calcium polyphosphate phase formed exclusively on PLA/PDA/n-HA. With cell viability assay, the PDA/n-HA-coated matrix was biocompatible with increase in the IC50, reaching ⁓176.8 at 72 without cytotoxic effect on the mesenchymal stem cells, promoting their adhesion and proliferation evaluated by confocal microscopy. The study explored the biocompatibility, bioactivity, and the cell adhesion ability of PDA/n-HA coat on a 3D-printed PLA scaffold that qualifies its use as a promising regenerative material.

Researching on the Effect of Input Parameters on the Quality and Manufacturability of 3D-Printed Cellular Samples from Nylon 12 CF in Synergy with Testing Their Behavior in Bending.

The study of cellular structures and their properties represents big potential for their future applications in real practice. The article aims to study the effect of input parameters on the quality and manufacturability of cellular samples 3D-printed from Nylon 12 CF in synergy with testing their bending behavior. Three types of structures (Schwarz Diamond, Shoen Gyroid, and Schwarz Primitive) were selected for investigation that were made via the fused deposition modeling technique. As part of the research focused on the settings of input parameters in terms of the quality and manufacturability of the samples, input parameters such as volume fraction, temperature of the working space, filament feeding method and positioning of the sample on the printing pad were specified for the combination of the used material and 3D printer. During the experimental investigation of the bending properties of the samples, a three-point bending test was performed. The dependences of force on deflection were mathematically described and the amount of absorbed energy and ductility were evaluated. The results show that among the investigated structures, the Schwarz Diamond structure appears to be the most suitable for bending stress applications.

Enhanced Bone Healing in Critical-Sized Rabbit Femoral Defects: Impact of Helical and Alternate Scaffold Architectures.

This study investigates the effect of scaffold architecture on bone regeneration, focusing on 3D-printed polylactic acid-bioceramic calcium phosphate (PLA-bioCaP) composite scaffolds in rabbit femoral condyle critical defects. We explored two distinct scaffold designs to assess their influence on bone healing and scaffold performance. Structures with alternate (0°/90°) and helical (0°/45°/90°/135°/180°) laydown patterns were manufactured with a 3D printer using a fused deposition modeling technique. The scaffolds were meticulously characterized for pore size, strut thickness, porosity, pore accessibility, and mechanical properties. The in vivo efficacy of these scaffolds was evaluated using a femoral condyle critical defect model in eight skeletally mature New Zealand White rabbits. Then, the results were analyzed micro-tomographically, histologically, and histomorphometrically. Our findings indicate that both scaffold architectures are biocompatible and support bone formation. The helical scaffolds, characterized by larger pore sizes and higher porosity, demonstrated significantly greater bone regeneration than the alternate structures. However, their lower mechanical strength presented limitations for use in load-bearing sites.

Investigating the impact of laser polishing parameters on surface roughness, mass ablation rate, and optical transmittance of 3D‐printed PLA substrates

AbstractLaser polishing technique is one of the most effective post‐processing methods for 3D‐printed Polylactic acid (PLA) substrates and has gained significant interest of scientific research community in past few years. This paper aims to investigate the effect of fill density, laser power, and scanning speed on the polishing responses of 3D‐printed PLA substrates. These include surface roughness, mass ablation rate, and optical transmittance of PLA substrates printed using the fused deposition modeling technique. The optical transmittance was measured using Fourier‐transform infrared spectroscopy technique and surfaces were characterized using scanning electron microscope, and optical microscope. Minimum surface roughness of 1.04 μm was achieved at 5% laser power and 55% fill density constituting a decrease of 61.8% from unpolished PLA (2.735 μm). The lowest mass ablation rate (0.015 μg/pulse) was observed for the specimens with 40% infill density. Higher scanning speed enhanced the molecular bonding in PLA‐55 specimen indicated by increased peak transmittance ratios of CH bonds at stretching (1.021) and bending modes (1.045).

A novel pellet-based 3D printing of high stretchable elastomer

Elastomers, known for their high stretchability and flexibility, are widely used in high-tech applications. However, traditional manufacturing methods for elastomeric part production have limitations. 3D printing, particularly fused deposition modeling (FDM), offers a promising alternative by allowing the fabrication of customized elastomers with desired shapes and properties. Conventional filament-based FDM techniques struggle to print elastomers. This article presents a novel approach for 3D printing polyolefin elastomer (POE) using a direct pellet printing technique. A customized pellet printer with a pneumatic pressure feeding system was used that eliminates filament buckling issues commonly associated with conventional filament-based 3D printing methods. The mechanical properties and microstructure of the printed parts were analyzed to evaluate the suitability of the technique for producing high-quality elastomeric components. SEM images indicated a high-quality and accurate printing method; however, there are micro-holes between the raster due to the high shrinkage rate of POE and increasing the nozzle temperature improves the print quality. The mechanical properties of the printed samples exhibited remarkable formability, with elongation reaching up to 1965%. It is also found that as the nozzle temperature increased, the strength, elongation, and bonding between layers improved significantly. This innovative 3D printing technique has the potential for various applications such as soft robotics and wearable electronics.

Compressive properties of a modified re-entrant chiral auxetic structure (MRCA) under uniaxial quasi-static loading

Auxetics are a unique class of innovative materials/structures. Auxetic material/structures possess a negative value of Poisson’s ratio owing to the distinguished deformation behavior represented by the transvers expansion or contraction when they experience uniaxial stretching or compression, respectively. The aim of this manuscript is to show contributions of the structural modification on an auxetic hybrid structure. The in-plane properties of an auxetic structure, called the modified re-entrant chiral auxetic (MRCA) structure under quasi-static compression were experimentally and numerically explored. The experimental specimens were 3D printed using fused deposition modeling technique. The commercial ABAQUS/Explicit solver was used to develop the simulated models. Results showed that the structural modification have led to effectively improve deformation coordination (i.e. uniform deformation patterns) and the compressive properties of the modified structure. Young’s moduli were 1.75 and 12.7 higher than those of the original geometry, while values of plateau stress were 3.1 and 1.23 higher than those of the original geometry when they were compressed along the X and Y axes, respectively. The specific energy absorptions per unit mass were 4.7 J g−1 and 3.9 J g−1 when the MRCA specimens were compressed along the X and Y axes, respectively. However, the added cylinders limited the auxeticity (i.e. the transvers contraction) of the specimens during the compression tests.

Topology optimization and 3D printing of a unibody quadcopter airframe

The performance of any unmanned aerial vehicle largely depends upon its weight as this characteristic dictates its payload capacity and flight duration. This paper presents a multiphysics simulation method for designing a unibody quadcopter airframe with optimum weight in SolidWorks. By adopting the computer-aided topology optimization concept, the mass of the frame is decreased by 91% (from 1558.44 to 134.738 grams) after getting rid of the unwanted elements, while not compromising its structural rigidity. The efficacy of the model is assessed by finite element analysis and it is found that the stress would remain within the acceptable limit. The optimized structure shows an operating life of 1.6×105 cycles in the fatigue analysis and experiences significantly less drag force in the computational fluid dynamics test than the original airframe for several angles of attack, thus proving the superiority of the optimized frame over the initial model. Finally, additive manufacturing is performed to fabricate the optimized structure using PLA material. 3D printing through the fused deposition modeling technique is chosen since it is ideal for fabricating intricate engineering prototypes compared to orthodox manufacturing processes. While creating the frame, a 45° overhang angle is maintained to ensure the usage of less support material.