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An assessment of 3D-printed span-change structures is presented for determining suitability of the technology to small unmanned aerial vehicles. Materials and manufacturing technologies were used with an emphasis on near term applicability with design trades between the aerodynamic performance and structural response. Aerodynamic performance was assessed on three wind tunnel models varying span (432, 600, and 762 mm), wind speed (Reynolds numbers 18,000, 36,000, and 71,000), additive manufacturing print build plane and camber, quantifying structural response as the resulting shape during aerodynamic loading. Each model displayed increasing compliance as span increased with wing-tip displacement on the order of 50, 100, and 200 mm with various degrees of sweep and twist. Models generated excess lift at Re = 71,000 indicating potential flight demonstration of the technology with a lift to drag improvement of up to 97% at maximum wing extension.

Assessment of 3D-printed span change structures applied to small unmanned aerial vehicles