A Comparison between 3D Printing and Milling Process for a Spar Cap Fitting (Wing-fuselage) of UAV Aircraft

Topology optimization is playing an important role in the aircraft design. The demand of lower fuel consumption reflects on the optimization of the airframe of flying vehicles to reduce the structure weight, therefore improving the fraction of the payload. This work focuses on the replacement of an existing part (spar cap fitting) with the new topologically optimized part to be manufactured with 3D printing (Selective Laser Sintering -SLS). The manufacturing constraints (minimum dimension, growth orientation) influence on the optimal results is evaluated to compare traditional milling process’ performance with the new SLS technique.