Topology Optimization for Drone Structure: Comprehensive Workflow Including Conceptual Modeling, Components Preparation and Additive Manufacturing

Payload drones are often limited more by frame weight than by motor power. This work aims to design, optimize, and validate a flat octocopter frame with eight independently driven rotors arranged symmetrically on separate arms. The drone frame design in SOLIDWORKS uses Finite Element Analysis (FEA) and topology optimization to remove material from low-stress regions while keeping the main load paths intact. The final design cuts the frame mass by 37.3% compared to the baseline model and reduces the 3D printing time by about five hours using a Creality K1C printer with Polylactic Acid (PLA) filament. These changes increase the available thrust-to-weight margin for payload without exceeding the allowable stress or deformation limits of the material. The electronic components also identified compatible flight controllers, ESCs, motors, and radio systems to show that the proposed frame can be integrated into a complete multirotor platform. Overall, this work demonstrates a practical approach to designing lighter octocopter frames that are easier to 3D print and can be used more effectively for delivery and inspection missions.