Increase Impact Resistance of Drones
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.
3. 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
4. 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.
5. Decentralized Drone Fleet Management with Lifecycle-Based Dispensing and Staggered Charging for 3D Image Display
UNIVERSITY OF SOUTHERN CALIFORNIA, 2025
Controlling large numbers of small flying drones to display 3D images without individual drone failures impacting image quality. The technique involves managing drone lifecycle, dispensing and retrieving drones based on battery and expected failure. It also separates drones into groups and uses decentralized conflict resolution to avoid collisions. This allows replacing failed drones quickly and efficiently. The technique also staggered charging of drone batteries during display to prevent simultaneous failures.
6. Hybrid Propulsion System with Engine Load Management for Multi-Rotor Drones
SAFRAN HELICOPTER ENGINES, 2025
Hybrid propulsion system for multi-rotor drones that can prevent engine overspeed during power demand reductions. The system uses an electric generator driven by the engine to create additional load on the engine when power demand drops. This prevents sudden speed increases that could damage the engine. If the generator fails, short circuiting means can be used to directly connect the engine to the load.
7. VTOL Electric Aircraft with Distributed Propulsion and Integrated Engine Cooling Systems
ARCHER AVIATION INC, 2025
Vertical takeoff and landing (VTOL) electric aircraft with optimized electric propulsion systems, cooling systems, and components for maximizing performance and efficiency while minimizing weight. The electric engines have reduced oil consumption to avoid fire hazards. The engines have features like low oil quantity, low air temperature, and non-hazardous air volume to prevent uncontained fires. The engines also have cooling systems using a mixture of air and liquid to manage heat. The engines communicate with flight control systems to adjust thrust and orientation. The aircraft uses distributed electric propulsion with multiple engines for redundancy. The engines are mounted directly to the fuselage and have lower weight and volume compared to conventional engines. The aircraft also has optimized gearboxes, motors, and heat exchangers for improved weight and performance.
8. Discrete-Time Integrated Guidance and Feedback Control System for Unmanned Vehicle Trajectory and Attitude Stabilization
SYRACUSE UNIVERSITY, 2025
Robust guidance and control for unmanned vehicles that allows autonomous navigation to waypoints while ensuring stability and robustness. The approach involves integrated guidance and feedback control that generates trajectories for both position and attitude. The position trajectory is tracked using a force along the vehicle's thrust direction. The attitude trajectory is generated based on the desired thrust direction. This allows finite-time stable attitude control. The overall system is discretized in time for computerized integration. The discretized dynamics and control are proven to have almost global asymptotic stability.
9. 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.
10. Passive Ice Protection Systems for Unmanned Aerial Vehicles Applications: A Review
lorenzo facco, riccardo parin, maria basso - Wiley, 2025
Abstract Unmanned aerial vehicles (UAVs) are promising platforms for operations in alpine regions due to their compact size, advanced camera systems, and ability take off land confined areas. In such conditions, one of the most significant challenges UAVs is operating icing environments, as ice accretion can compromise aerodynamics propellers potentially lead fto a loss control vehicle failure. To date, active deicing solutions, electrothermal have been employed aeronautical sector; however, these systems energyintensive. This review addresses passive protection from material science prospective, by focusing on coatings which mitigate formation without energy consumption. A comprehensive description strategies design an icephobic surface presented stateoftheart analyzed, superhydrophobic surfaces, elastomers, liquid infused gels, polyelectrolytes, sol gel coatings, metalorganic frameworks. key focus devoted characterizations assessing mitigation i.e., contact angle hysteresis measurements, correlation between durability number cycles. The relevant solutions describe... Read More
11. 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.
12. 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
13. 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.
14. Aerodynamic Bearing with Deformable Radial Expansion Inner Surface for Brushless Motors
DYSON TECHNOLOGY LTD, 2025
Aerodynamic bearing for brushless motors that improves performance, efficiency, reliability, and noise compared to traditional rolling bearings. The aerodynamic bearing has a deformable inner surface that can expand radially to accommodate shaft motion. This allows the bearing to support the shaft without tight tolerance fits or rollers, reducing friction and heat. The deformable inner surface is made of materials like elastomer or plastic. This allows the bearing to conform to the shaft and reduce drag as it spins. The deformable inner surface can be continuously annular or integrated with the bearing support. The bearing can be used in brushless motor rotor assemblies to replace rolling bearings, providing benefits like quieter operation, longer life, and reduced size/weight.
15. 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.
16. Electric Motor with Labyrinthine Seal and Lightweight Composite Housing for Aircraft
JOBY AERO INC, 2025
An electric motor for aircraft with improved sealing and reduced weight compared to conventional motors. The motor has a unique sealing design that prevents debris ingress while minimizing friction losses. The rotor housing has a convoluted groove at one end. A sealing ring with protrusions fits into the groove. This labyrinthine seal prevents debris from reaching the interior of the rotor while allowing rotation without contact. The groove shape reduces mass compared to a solid housing. The motor also uses lightweight materials like titanium for the housing and an aluminum honeycomb ring to facilitate heat transfer.
17. Amphibious Unmanned Aerial System with Sealed Electronics and Mid-Air Recovery Mechanism
ALAN R TAYLOR, 2025
Amphibious unmanned aerial system (UAS) that can operate in water environments and endure extended contact with water. The UAS has features like sealed electronics, water-resistant components, and buoyancy aids to enable amphibious operation. The UAS also has a specialized recovery system that captures the UAS mid-air before it touches the ground or water to prevent damage to components not designed for hard landings.
18. Design, Dynamics and Development of Upgraded Tiltable Wing associated Quadcopter through Advanced computational simulations incorporated Bottom-Up Approach
haribalan saravana mohan, karthikeyan murugaraj, senthil kumar solaiappan - Nature Portfolio, 2025
This paper aims to design a hybrid quadcopter that can be used for multiple detecting applications in which its performance parameters are studied under various maneuverings such as forward and vertical movements based on computational studies. In order enhance the endurance, conventional rectangular cross-sectional arm was replaced by airfoil cross sectional helps reduction of overall drag. The proposed idea is combination both tilt wing rotor configurations unmanned aerial vehicle (HUAV). CAD modeling UAV components propeller done using Autodesk Fusion 360 fluid flow analysis carried out ANSYS Workbench 23 software. Different test cases including Computational dynamics (CFD), Fluid structure interaction (FSI) executed estimate configuration. Analyzing from stability point view, mathematical model designed control altitude increment, hold velocity accordingly, tuning controller taken over. capable attaining during harsh environments analyzed study processes executed. As preliminary work validation, grid convergence performed obtain reliable outcome over, addition execution analytica... Read More
19. 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.
20. Drone Battery Casing with Nano-Ceramic Aluminum Alloy Lattice Structure
CHONGQING ELECTROMECHANICAL ADDITIVE MANUFACTURING CO LTD, CHONGQING ELECTROMECHANICAL ADDITIVE MFG CO LTD, 2023
A drone battery casing made of a lattice structure that provides improved protection and heat dissipation compared to traditional casings. The casing is made of nano-ceramic aluminum alloy and has a periodic lattice structure. It replaces machined casings made of materials like PC or aluminum. The lattice structure enhances stiffness and force resistance while dissipating heat better than solid casings. The lattice casing provides better protection for the drone battery during flight compared to traditional casings.
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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