Aerodynamics Analysis of a Novel Multirotor Structure Derived from Generative Design Using Computational Fluid Dynamics

This study investigates whether generative design structures can enhance the aerodynamic efficiency and payload capacity of multirotor UAVs compared with conventional stacked-rotor layouts. The methodology integrated structural generative design in Autodesk Fusion 360 and evaluated hover aerodynamics using computational fluid dynamics (CFD) analysis in SimScale, employing a steady, pressure-based incompressible RANS solver and Multiple Reference Frame (MRF) zones to model hover at 4500 rpm. Three configurations were evaluated: a baseline “Initial Model” and two generative-design outcomes (Model 1 and Model 3). The results show that Model 1 provides negligible improvement, whereas Model 3 increases total thrust to 42.36 N, corresponding to a 9.6% gain relative to the initial configuration, and raises the system-average figure of merit by approximately 65%. Flow-field analyses indicate that Model 3 promotes cleaner inflow to the upper tier and a more coherent downwash, with reduced recirculation and interference-related losses. The novelty lies in coupling generative structural synthesis with CFD-based aerodynamic screening to demonstrate that frame geometry can actively enhance stacked-rotor hover performance.