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Title: Fabrication of design-optimized multifunctional safety cage with conformal circuits for drone using hybrid 3D printing technology
Authors: Goh, Guo Liang
Dikshit, Vishwesh
Koneru, Rahul
Peh, Zhen Kai
Lu, Weiyao
Goh, Guo Dong
Yeong, Wai Yee
Keywords: Engineering::Mechanical engineering
Issue Date: 2022
Source: Goh, G. L., Dikshit, V., Koneru, R., Peh, Z. K., Lu, W., Goh, G. D. & Yeong, W. Y. (2022). Fabrication of design-optimized multifunctional safety cage with conformal circuits for drone using hybrid 3D printing technology. International Journal of Advanced Manufacturing Technology, 120(3-4), 2573-2586.
Journal: International Journal of Advanced Manufacturing Technology 
Abstract: The ability to design and fabricate lightweight structure is one of the most important aspects for building a drone system. Often, connecting wires are used on the drone system for powering and signal transmission at the expense of the drone’s weight. In this paper, we explore the design and fabrication of a safety cage for drone using design optimization and 3D printing. A comparison between fused deposition modelling (FDM) and selective laser sintering (SLS) 3D printing techniques for the fabrication of thin structures was made, and it was found that SLS is more superior in this aspect. A hybrid 3D printing process combining SLS and aerosol jet printing is proposed for the fabrication of lightweight multifunctional structure with printed circuit for a drone safety cage. The safety cage is designed in such a way that maximizes the production efficiency of SLS printing process. In addition, aerosol jet printing is used to fabricate conformal circuit onto the 3D-printed safety cage structure to replace the conventional connecting wires for weight saving purpose. Lastly, an electrical characterization is conducted to investigate the functionality of the printed conductive traces on the safety cage. Nevertheless, this work demonstrates the streamlining of various 3D printing approaches for the fabrication of multifunctional structures with conformal circuits.
ISSN: 0268-3768
DOI: 10.1007/s00170-022-08831-y
Schools: School of Mechanical and Aerospace Engineering 
Research Centres: Singapore Centre for 3D Printing 
Rights: © 2022 The Author(s), under exclusive licence to Springer-Verlag London Ltd., part of Springer Nature. This is a post-peer-review, pre-copyedit version of an article published in International Journal of Advanced Manufacturing Technology. The final authenticated version is available online at:
Fulltext Permission: open
Fulltext Availability: With Fulltext
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