Strength-Based Design Assessment of an Additively Manufactured Pusher-Duct Support Bracket for a Novel UAV Prototype Applicable to Agricultural Use

Celik, H. Kursat and Erbil, M. Ali and Rennie, Allan and Akinci, Ibrahim (2026) Strength-Based Design Assessment of an Additively Manufactured Pusher-Duct Support Bracket for a Novel UAV Prototype Applicable to Agricultural Use. Journal of Agricultural Machinery Science, 22. pp. 15-31. ISSN 1306-0007

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Abstract

Unmanned Aerial Vehicles (UAVs) are increasingly deployed in defence, surveillance, and precision agriculture, requiring lightweight yet robust structural components capable of withstanding demanding operational conditions. Ensuring the strength and reliability of additively manufactured support brackets is critical for UAV integrity. The aim of this study is to investigate the structural response of a pusher duct support bracket, designed for integration into a next-generation UAV prototype, under critical loading conditions. The investigation focused on bracket deformation during the UAV’s immediate take-off phase, considered one of the most severe mechanical scenarios. A CAD/CAE-based workflow was adopted, integrating numerical simulation techniques. A parametric solid model of the bracket was created, and Finite Element Analysis (FEA) using SolidWorks Simulation was employed to assess stress distribution and deformation. FEA revealed the maximum von Mises equivalent stress as 14.951 MPa at fastener locations, with peak deformation of 0.378 mm at the front tip. The minimum Factor of Safety (FoS) was 1.739 at the flange of the front fastener, while other regions exhibited considerably higher FoS values. These findings demonstrate that the bracket is structurally adequate for its intended application, although stress concentrations remain evident. While the additively manufactured bracket performs safely under critical loading, reinforcing fastener flanges and applying topological optimisation could improve stress distribution and achieve mass reduction without compromising structural integrity.