Unmanned aerial vehicles operating in challenging environments face multiple structural and mechanical stresses that can significantly reduce their operational lifespan. Field data shows that landing impacts, dust infiltration, and collision events account for over 70% of drone failures, with mean time between failures often falling below 100 flight hours for commercial units.

The fundamental challenge lies in balancing structural durability against the critical requirements of weight minimization and aerodynamic efficiency.

This page brings together solutions from recent research—including protective outer cage designs with impact-decoupling mechanisms, dust-resistant motor assemblies, retractable landing systems, and reinforced signal line protection schemes. These and other approaches focus on extending drone longevity while maintaining performance in real-world operating conditions.

1. Hub-Integrated Skid Surface for Rotor Shaft Protection in Unmanned Aerial Vehicle Motors

AeroVironment, Inc., 2023

A motor designed for unmanned aerial vehicles (UAVs) to prevent damage when landing on rough terrain. The motor has a hub with a skid surface that contacts the motor casing during propeller strikes on the ground. This reinforcement prevents excessive bending of the rotor shaft, which could damage the motor.

2. Removable Deformable Lateral Bumpers for Quadcopter Drone Propeller Protection

PARROT, 2015

Removable protection for quadcopter drones that provides propeller protection without adding bulk when not needed. The protection consists of removable lateral bumpers that extend beyond the propeller's rotation area. A deformable arm connects Each bumper to the drone's propulsion units on that side. The arm can flex if the bumper hits an obstacle, reducing shock and preventing damage.

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3. UAV Flight State-Based Adaptive Protection System for Positioning System Failure

AUTEL ROBOTICS CO LTD, 2025

Protecting unmanned aerial vehicles (UAVs) from crashing when their positioning systems fail. The method involves determining the UAV's flight state based on its speed before positioning loss, and then adjusting flight protection strategies accordingly. If the UAV was flying slowly before, it enters a low-speed protection mode. If flying fast, it enters a high-speed protection mode. This reduces explosion probability and improves safety after positioning loss compared to the UAV's default flight mode.

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4. Additively Manufactured Airframe Structure with Internally Reinforced Segment Linkage

RAPIDFLIGHT HOLDINGS LLC, 2025

An additive manufactured airframe structure for aerospace applications that enables assembling multiple components into a complete structure without losing mechanical properties. The structure uses separate additively manufactured segments that are linked together. Inside each segment, reinforcement elements like rods or tubes extend through the segment and are received in internal hollow portions. This provides internal reinforcement for the assembled structure without losing strength from external connections. The segments can form wings, fuselages, etc.

5. Autonomous Aerial Vehicle with Modular Rotor Blades, Image Sensor Protective Structure, Gimbal Locking Mechanism, and Fixed-Wing Configurations

SKYDIO INC, 2025

Autonomous aerial vehicle design with features like modular removable rotor blades, a protective structure for image capture devices, a gimbal locking mechanism, and fixed-wing configurations. The removable rotor blades simplify replacement compared to traditional propeller nuts and prevent spontaneous loosening. The protective structure shields the image sensors from impact. The gimbal locking mechanism secures the camera when the vehicle is powered off to prevent damage. Fixed-wing configurations enable high-speed flight and long range compared to rotor-only designs.

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6. Drone System with Interconnected Modular Units and Independently Oriented Enclosed Propellers

AERBOTS INC, 2025

A drone system with physically connected drones for improved efficiency, durability, and swarming capabilities. The drones in this system have multiple propellers enclosed within a central core with arms extending outwards. This allows the propellers to be oriented independently from the drone body. The drones also have mechanisms to connect and disconnect from each other, forming a chain. This allows the connected drones to share thrust and power, improving efficiency. It also provides physical connections between the drones, enabling cooperative maneuvers like formations and swarming. The enclosed propellers also protect them from debris and damage.

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7. Triangular Bracket with Dual Horizontal and Single Vertical Shock-Absorbing Elements for UAV Camera Stabilization

AUTEL ROBOTICS CO LTD, 2025

Shock-absorbing bracket for unmanned aerial vehicles (UAVs) that reduces vibrations transmitted to the camera during flight. The bracket has a triangular architecture with two horizontal shock-absorbing elements on one side and a vertical shock-absorbing element on the other side. This configuration provides better stability and minimizes front/rear deformation compared to having all shock absorbers on one side. The bracket attaches the camera to the UAV and helps maintain stable image capture in flight by absorbing vibrations.

8. Unmanned Aerial Vehicle with Protective Cage and Magnetically Coupled Load-Limiting Sensor Mounts

FLYABILITY SA, 2025

An unmanned aerial vehicle (UAV) with a protective outer cage and a sensor system that can withstand impacts without damaging the sensors. The UAV has an outer protective cage surrounding the propulsion system. The sensors are mounted on a fixed support outside the cage. The sensors are coupled to the support using a load-limiting mechanism with magnetic connections. This allows the sensors to move slightly under low loads for stability, but prevents damage from high impacts by deforming the spring-loaded mechanism and transferring the force to the cage frame.

9. Centrifugal Clutch with Sequential Engagement Elements for Incremental Angular Displacement in Rotorcraft Bearings

TEXTRON INNOVATIONS INC, 2025

Centrifugal clutch for rotorcraft bearings that allows controlled slippage to prevent overloading and premature failure of the bearing under torsional loads. The clutch has multiple activation elements that sequentially engage and disengage as the bearing rotates, allowing incremental angular displacement without fully locking. This prevents excessive torsional deflection of the bearing elastomeric elements and prevents premature failure. The sequential engagement opens up windows of angular operation as the rotor spins up, allowing controlled slippage instead of overloading the bearing elastomer.

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10. Composite Structure with Fiber-Modified Interlayers for Enhanced Impact Resistance and Conductivity

THE BOEING CO, 2025

Composite materials for structures like aerospace components that have improved impact resistance, electrical conductivity, and lightning strike protection compared to traditional composites. The improvement comes from adding fiber-modified interlayers between the fiber layers during composite fabrication. These interlayers contain a nonwoven fabric made of continuous fibers with discontinuous fibers attached to it. This provides a conductive path between the fiber layers for lightning strike dissipation. It also allows impact energy to be deflected laterally rather than propagating through the thickness of the composite. The interlayers are arranged alternately with the fiber layers to make the composite.

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11. Effect of multi-cell approach on crashworthiness performance of 3D-printed thin-walled structures under lateral compression loading for unmanned aerial vehicle applications

m gokhan atahan, halil zeybek - SAGE Publishing, 2025

Recent technological advancements in unmanned aerial vehicles have led to their use various military and civilian applications. However, weather conditions, operator faults, electronic or mechanical problems can result vehicle accidents. In the event of an accident, energy-absorbing structures be placed specific regions protect sensitive costly cameras, sensors, cargo from damage, while also preserving vehicle's structural integrity. this study, thin-walled energy absorbers with circular, square, hexagonal, reentrant geometries were proposed, experimental investigation focused on effect increasing number cells crashworthiness performance deformation mechanisms. Lateral compressive load was applied produced by fused deposition modeling technology using advanced polylactic acid filament. Experimental results showed that triple-cell structure demonstrated promising for applications, as it exhibited highest mean crushing force, absorption, absorption values. Thanks unique geometry structure, a gradual collapse mode observed, result, high performance.

12. Remanufacturing of Damaged Parts From a UAV

madalinaioana blaj, gheorghe oancea - Wiley, 2025

Abstract In the evergrowing world of unmanned aerial vehicles (UAVs), also known as drones, keeping these machines operational can be a costly endeavor. Replacing damaged parts expensive, but promising solution is emerging: remanufacturing considering additive manufacturing. This article explores potential fused deposition modeling (FDM) process for UAV parts, offering sustainable and costeffective approach to drone maintenance, current European Union Aviation Safety Agency (EASA) regulations. For particular case, are remanufactured with PET CF15 composite filament tested loading case in Z direction (vertical direction) order compare behavior original assembly.

13. Composite Filament Materials for 3D-Printed Drone Parts: Advancements in Mechanical Strength, Weight Optimization and Embedded Electronics

antreas kantaros, christos drosos, michail papoutsidakis - Multidisciplinary Digital Publishing Institute, 2025

The rapid advancement of 3D printing technologies has greatly assisted drone manufacturing, particularly through the use composite filaments. This paper explores impact fiber-reinforced materials, such as carbon-fiber-infused PLA, PETG, and nylon, on mechanical performance, weight optimization, functionality unmanned aerial vehicles (UAVs). study highlights how additive manufacturing enables fabrication lightweight yet structurally robust components, enhancing flight endurance, stability, payload capacity. Key advancements in high-speed fused filament (FFF) printing, soluble support embedded electronics integration are examined, demonstrating their role producing highly functional UAV parts. Furthermore, challenges associated with material processing, cost, scalability discussed, along solutions advanced extruder designs hybrid approaches that combine CNC machining. By utilizing filaments innovative techniques, continues to redefine production, enabling prototyping on-demand customization. nylon demonstrated outstanding improvements strength-to-weight structural durability, dimension... Read More

14. eVTOL Multirotor Aircraft with Sensor-Driven Propeller Thrust Control for Active Flutter Suppression

AIRBUS HELICOPTERS DEUTSCHLAND GMBH, 2025

Electrically powered vertical takeoff and landing (eVTOL) multirotor aircraft with active flutter suppression using propeller thrust control. The aircraft has sensors to detect flutter of the lifting surfaces like wings, and a control system adjusts propeller thrust to reduce flutter. This active flutter mitigation prevents instability caused by aeroelastic coupling of structural motion and aerodynamic loads. The sensors detect flutter, the control system generates signals to adjust propeller thrust, and the propellers produce modified thrust to counteract flutter motion and stabilize the lifting surfaces.

15. Ball-and-Socket joint produces longitudinal and lateral control with a horizontal feathered tail for small uncrewed aerial systems

todd henry, kevin haughn, madeline morales - SAGE Publishing, 2025

This work presents the development of a novel, articulated small uncrewed aerial system (sUAS) tail with coupled twist-pitch motion via ball-and-socket joint. The joint is controlled by five-bar linkage which allows two servos to together in motion, as opposed dedicated traditional elevator and rudder servo control. constructed synthetic feathers slide over one another splay degree freedom third servo. Additive manufacturing leveraged construction all parts wind tunnel model continuous carbon fiber (CCF) reinforcement, increased structural stiffness from 12 GPa for Nylon 1520 CCF reinforcement. Wind test results are presented 5 7 m/s speed body angles of-5 45 angle attack articulation 30 45 respectively. design was capable enabling fine five axis control (e.g., no roll moment control) pitch twist morphing across broad range airspeeds.

16. Design and Development of Drone Recovery System Using Parachute

k mahajan, prathmesh kashid, abhijeet boralkar, 2025

Unmanned Aerial Vehicles (UAVs), or drones, have become increasingly important in various fields, including aerial photography, delivery services, and surveillance. However, as drone usage has expanded, so the risks related to system failures accidents. Such can result expensive damages even threaten public safety. A promising way address these is by implementing a recovery that uses parachute mechanism. This paper discusses design, development, implementation of parachute-based for drones. It looks into essential components system, such selection, deployment methods, material choices, performance testing. The goal improve safety operations ensuring controlled descents during emergencies, thus minimizing risk crash-related damage.

17. Sustainable composite materials for UAVs: An analysis of Morinda citrifolia and Tamarindus indica bio-fibres

m vinothkumar, b kirubadurai, r jaganraj - Akadémiai Kiadó, 2025

Abstract Nowadays, aligned with the national mission, growth of Unmanned Aerial Vehicle (UAV) application is enormous. This research work investigates probability adding epoxy resin novel biofibres such as Tamarindus indica and Morinda citrifolia to fabricate a composite material. A sustainable outcome delivered by adopting fibres in UAV frame materials, which combine increased mechanical strength durability good environmental conditions. Based on test outcomes, (ETI) indicates significant compressive an optimum load-carrying capacity 5.98 kN notable tensile maximum 8.13 MPa, therefore plate can be used rigid or definite-shaped applications due its high resistance deformation. The (ETC) indicated flexibility rate carrying flexural load (0.15 KN), so it dampening cushioning material absorb vibrational energy. These two biodegradable materials possess lower density higher strength-to-weight ratio, are important properties for decreasing power consumption improving UAV's endurance. We investigated chemical morphological characteristics composites using scanning electron microscopy (SEM)... Read More

18. Helicoidal Composite Material with Layered Spiral Architecture

HELICOID INDUSTRIES INC, 2025

Helicoidal composite materials with improved impact resistance and damage tolerance. The materials have a unique layered structure that spirals around the part, rather than being flat. This helical architecture allows for more design freedom and tailoring of the composite properties. The helical layup can be made using thin ply unidirectional (TPUD) fabric, thin ply woven fabric (TPW), or quasi-unidirectional woven fabric (QUDW). The helical layup provides better impact resistance compared to traditional flat layups because it allows for more controlled fiber orientation and delamination prevention.

19. Inertial Measurement Module with Thermally Conductive Member and Counterweight Assembly

AUTEL ROBOTICS CO LTD, 2025

An inertial measurement module, shock absorption system, and unmanned aerial vehicle (UAV) with improved accuracy and stability of flight control. The module has a thermally conductive member between the inertial measurement unit and a thermal resistor. This allows heat from the resistor to transfer to the measurement unit without squeezing them together. A counterweight assembly prevents contact between the thermally conductive member and the module housing. This prevents the module from squeezing and reduces stress changes on the measurement unit due to temperature.

20. Drone with Partitioned Fuselage and Detachable Wings Featuring Torsion Spring-Connected Impact Cushioning

NINGBO DENGHOU TECH CO LTD, NINGBO DENGHOU TECHNOLOGY CO LTD, 2024

A drone design to improve heat dissipation and impact resistance. The drone has a main body with a fixed bottom fuselage and detachable wings. Inside the fuselage, components like the camera and motors are separated by partitions with heat insulating film to prevent heat transfer between components. A torsion spring connects the fuselage to the main body, allowing it to expand and cushion impacts.

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21. Drone Battery Casing with Nano-Ceramic Aluminum Alloy Lattice Structure

22. Unmanned Aerial Vehicle with Gimbal-Connected Protective Outer Cage and Actuation System

23. Modular Carbon Fiber Unmanned Aerial Vehicle Body with Interspersed Glue Joints and Bolt Fixation

24. Multi-Layer Anisotropic Damping Structure with Shock-Absorbing Sponges for UAV Flight Control Systems

25. Drone with Double Monocoque Structure for Enhanced Strength and Customizable Exterior

Drones are becoming more trustworthy and durable for a variety of applications via improvements like retractable landing gear for increased aerodynamics and motors strengthened by skids for rough landings. Progress in weight reduction and safety are creating opportunities for a durable, sturdy drone future.

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