Rapid Manufacturing of Lightweight Drone Frames Using Single-Tow Architected Composites

The demand for lightweight and high-strength composite structures is rapidly growing in aerospace and robotics, particularly for optimized drone frames. However, conventional composite manufacturing methods struggle to achieve complex 3D architectures for weight savings and rely on assembling separate components, which introduce weak points at the joints. Additionally, maintaining continuous fiber reinforcement remains challenging, limiting structural efficiency. In this study, we demonstrate the lightweight Face Centered Cubic (FFC) lattice structured conceptualization of drone frames for weight reduction and complex topology fabrication through 3D Fiber Tethering (3DFiT) using continuous single tow fiber ensuring precise fiber alignment, eliminating weak points associated with traditional composite assembly. Mechanical testing demonstrates that the fabricated drone frame exhibits a high specific strength of around four to eight times the metal and thermoplastic, outperforming other conventional 3D printing methods. The drone frame weighs only 260 g, making it 10% lighter than the commercial DJI F450 frame, enhancing structural integrity and contributing to an extended flight time of three minutes, while flight testing confirms its stability and durability under operational conditions. The findings demonstrate the potential of single tow lattice truss-based drone frames, with 3DFiT serving as a scalable and efficient manufacturing method.