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Bachelor's Thesis
Author of thesis: Kryštof Sládek
Acad. year: 2025/2026
Supervisor: Ing. Ondřej Vaverka, Ph.D.
Reviewer: Ing. Vítězslav Sobol
This thesis addresses the design of an optimised quadcopter arm for the DJI F450 frame, made of AlSi10Mg and manufactured by Powder Bed Fusion (PBF). The aim was to achieve significantly higher stiffness at a mass comparable to the original plastic component. The work combines topology optimization with lattice structure design and presents methodology for designing additively manufactured parts with an optimal mass-to-stiffness ratio. From a comparison of eight unit cell types, Gyroid (TPMS) and Body-Centered Cubic (strut-based) were selected. The arm geometry results from topology optimization using the Solid Isotropic Material with Penalization (SIMP) method and is filled with a graded structure whose thickness is modulated by the stress field via Field-Driven Design. Both variants were manufactured and compared photogrammetrically. The Gyroid variant outperformed BCC by 58 % in specific stiffness and was used in the final design. The simulation-experiment discrepancy is discussed separately and attributed to manufacturing limitations and to the altered mechanical properties of thin-walled PBF structures, consistent with the literature. Nevertheless, the final 53.5 g arm achieves more than 17× higher stiffness than the plastic original. Four such arms then successfully completed a test flight.
topology optimization, lattice structures, powder bed fusion, AlSi10Mg, drone
Date of defence
12.06.2026
Result of the defence
Defended (thesis was successfully defended)
Grading
A
Process of defence
Student prezentoval výsledky své bakalářské práce a zodpověděl otázky oponenta. Jakou měrou se na navýšené tuhosti podílí zvolený materiál a jakou optimalizovaná geometrie? Resp. jakou (měrnou) tuhost by měla navržená geometrie, pokud by byla vyrobena z původního materiálu PA66+CF, nebo jemu podobnému, např. technologií Selective Laser Sintering? - zodpovězeno prof.Vrbka - Proč jste volil dražší materiál než je původní? - zodpovězeno Je důležitá tuhost nebo pružnost a únosnost? - zodpovězeno Ing.Kvarda - Je uvažovaná boční tuhost? - zodpovězeno Měla by vliv vlastní frekvence? - zodpovězeno Doc.Galas - Jak jste analyzoval graf na 7 slidu? - zodpovězeno
Language of thesis
Czech
Faculty
Fakulta strojního inženýrství
Department
Institute of Machine and Industrial Design
Study programme
Fundamentals of Mechanical Engineering (B-ZSI-P)
Specialization
Fundamentals of Mechanical Engineering (STI)
Composition of Committee
prof. Ing. Martin Vrbka, Ph.D. (předseda) doc. Ing. Radovan Galas, Ph.D. (místopředseda) Ing. František Vlašic, Ph.D. (člen) Ing. Daniel Kvarda, Ph.D. (člen) Ing. Ondřej Vaverka, Ph.D. (člen)
Supervisor’s reportIng. Ondřej Vaverka, Ph.D.
Grade proposed by supervisor: A
Reviewer’s reportIng. Vítězslav Sobol
Grade proposed by reviewer: A
Responsibility: Mgr. et Mgr. Hana Odstrčilová