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. 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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4. 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.

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

Flyability SA, 2023

An unmanned aerial vehicle (UAV) with a protective outer cage provides high collision resistance while allowing maneuverability and access to inner components. The UAV has an inner frame with flight propulsion, an outer frame connected by a gimbal system, and an actuation system to actively orient the outer frame relative to the inner frame. This allows the outer cage to protect inner components from collisions while still reaping benefits like protection from the outer frame. The actuation can be through outer propellers or electrical actuators on the gimbal connections.

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

WANG MENGJUN, 2023

Full carbon fiber unmanned aerial vehicle body that uses interspersed glue joints between modular sections to create a lightweight, high-strength, and easily assembled body structure. The modular sections are made of carbon fiber composite material to reduce weight compared to metal bodies. The interspersed glue joints involve inserting an interspersed block into a slot on one section and fixing it with high-temperature glue. Then bolts are used for additional fixation. This allows modular sections to be spliced together into a complete body. The modular design enables customization and repairability while the carbon fiber composite material provides lightweight strength.

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

TIANJIN PEGASUS ROBOT TECH CO LTD, TIANJIN PEGASUS ROBOT TECHNOLOGY CO LTD, 2022

A vibration damping structure for unmanned aerial vehicles (UAVs) to improve flight stability and prevent damage to the flight control system from high-frequency vibrations. The damping structure uses multiple layers of shock-absorbing sponges sandwiched between positioning sheets and housings. The sponges are bonded to the flight control components and housings. The sponges are made of materials like viscose and glass fiber to provide anisotropic damping. The housings have positioning bosses and holes to securely mount the damping components. The sponges are positioned between the control components and housings to absorb vibrations in all directions.

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

TOKO TEKKO KK, 2022

Double monocoque structure for drones that enhances strength and waterproofing while allowing easy exterior customization. The drone has an internal monocoque covering the frame from above and below, with an external monocoque doubling over the internal one. This provides a double-layered monocoque structure around the drone components like wings, legs, and power source. The monocoque construction increases strength and waterproofing compared to just attaching lids to the frame. The double monocoque allows customizable outer shapes by changing the external monocoque design.

9. Foam-Polycarbonate Composite UAV Airframe with Enclosed Cores and Central Support Frame

FLIR Unmanned Aerial Systems ULC, 2022

A UAV architecture that provides improved thrust efficiency, mass reduction, protection, and internal cooling for unmanned aerial vehicles (UAVs). The architecture uses a foam-polycarbonate composite airframe with enclosed cores and a central support frame. The foam cores are vacuum formed polycarbonate shells overmolded with expanded polystyrene foam. This provides lightweight, impact-resistant airframe components. The enclosed cores shield internal components from damage. The support frame physically couples the cores and motors. The architecture enables upside-down landing/takeoff, buoyancy, and internal cooling through the foam cores.

10. Adjustable Heat Dissipation System with Detachable Heat Sink Fan and Impact-Absorbing Buffer Assembly for Multi-Rotor Drones

Jiangsu Xianglong Intelligent Equipment Technology Co., Ltd., Jiangsu Yufeng Offshore Wind Power Co., Ltd., 2021

Heat dissipation system for multi-rotor drones that allows customized heat dissipation and protection for different drone models. The system has a detachable heat sink fan mounted on the drone body, with a sliding adjustment rod to raise or lower the fan height. The fan slides in a frame that connects to the drone body. This allows the user to adjust the fan position based on drone size to ensure proper cooling. The system also has a buffer assembly at the drone bottom with a stopper, spring, cushion, and anti-collision pads to absorb impacts and protect the battery. This prevents damage when the drone lands.

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11. Unmanned Aerial Vehicle with Releasable Sensor-Cage Coupling Mechanism

Flyability SA, 2021

Unmanned aerial vehicle (UAV) with a protective outer cage and a sensor system like a camera. The cage protects the inner components from collisions, but can interfere with sensors and cameras. To solve this, the UAV has a releasable coupling between the sensors and the cage. The coupling is rigid in normal operation, but can release when subjected to a collision force above a threshold. This allows the sensors to be decoupled from the cage upon impact, protecting them from damage.

12. Modular Multi-Rotor Drone with External High-Voltage Component Configuration

SZ DJI TECHNOLOGY CO LTD, 2021

Modular multi-rotor drone design that allows quicker repair and continued operation after damage by separating high-voltage components from low-voltage components. The high-voltage components like batteries and motors are located outside the drone body. This protects them from damage during crashes. The low-voltage components like electronics and sensors are inside the body. If a high-voltage component fails, it can be quickly replaced without disassembling the entire drone. This enables faster repairs and allows the drone to be back in service sooner.

13. Modular Unmanned Aerial Vehicle with Protective Propeller Cages and Detachable Components

VANTAGE ROBOTICS, LLC, 2021

Improving the safety, durability, and modularity of unmanned aerial vehicles (UAVs) that protect the propellers from damage and reduce injury risk in case of impact. The UAV has a protective cage around each propeller that allows airflow through. The propeller assemblies are modular and can release upon impact to minimize damage. The UAV also has modular components like battery packs that can detach on impact.

14. Motor Hub with Radially Extending Carbon Fiber Spokes and Protective Pod Structure for Propeller Encapsulation

VANTAGE ROBOTICS, LLC, 2021

Improved motor hub and pod configurations for protecting propellers of unmanned aerial vehicles (UAVs) from damage during flight. The motor hub features a central hub with slots to receive carbon fiber spokes that extend radially outward to a protective outer ring. The spokes are oriented to resist flexure out of the plane of rotation, reducing the chances of blade strikes. The pod incorporates a rugged protective structure with ribs, hoops, and rims to encase the propellers. The motor hub and pod designs are lightweight, durable, and resistant to impacts that can damage conventional UAVs.

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15. Expandable Balloon-Covered Multi-Rotor Aircraft Configuration with Buoyancy Control and Pressure Ventilation

PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO, LTD., 2021

An aircraft configuration comprised of multiple rotor units covered by an expandable balloon. The balloon acts as a shock absorber and expands to provide cushioning if the aircraft crashes. The balloon contains a gas that can be released to control its buoyancy. It also has ventilation holes to prevent it from bursting due to pressure changes.

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16. Carbon Fiber Drone Fuselage with Integrated Frame, Bosses, Support Assemblies, and Arc Grooves

GUANGDONG AIMASHI NEW MATERIAL TECH CO LTD, GUANGDONG AIMASHI NEW MATERIAL TECHNOLOGY CO LTD, 2020

Integrated carbon fiber drone fuselage structure that provides a lightweight, strong, and corrosion-resistant drone body. The fuselage is made entirely of carbon fiber components like the frame, support assemblies, and bosses. The carbon fiber material's properties of light weight, high temperature resistance, friction resistance, and corrosion resistance are leveraged. The fuselage design features carbon fiber components like a frame, bosses, support assemblies, and arc grooves. The bosses attach to the frame and boom, the arc grooves connect to the boom, and the support assemblies provide corner stiffness.

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17. Unmanned Aerial Vehicle with Integrated Shock-Absorbing Support and Fixed Tail Rotor Shaft Configuration

Ehang Intelligent Equipment Co., Ltd., 2019

Shockproof unmanned aerial vehicle (UAV) to prevent internal components from vibrating and jumping during flight. The UAV has a fuselage, main rotor, tail rotor, engine, and reduction gearbox. The main rotor is directly connected to the fuselage, while the tail rotor is connected to the fuselage via a fixed shaft inside the fuselage. This prevents the tail rotor shaft from extending far into the fuselage and jumping during flight. The UAV also has a cooling system, landing gear, thrust amplifier, and shock-absorbing support assemblies.

18. Buffer System Activation Mechanism for Uninhabited Airborne Vehicles

OPTIM CORPORATION, 2017

A drone (uninhabited airborne vehicle) that reduces impact when it crashes to enhance safety. The drone has a buffer system to protect it from damage in case of a crash. The buffer system can be activated based on parameters such as battery charge level, altitude, distance to objects, and velocity. It wraps around the drone to absorb impact forces during a crash. The buffer driving process is activated when sensors detect conditions indicating a crash is imminent. This allows the drone to land with reduced impact forces to prevent damage.

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19. Modular Three-Section Wing with Trapezoidal Cross-Section and Foam-Filled Composite Structure

NAT UNIV DEFENSE TECHNOLOGY PLA, NATIONAL UNIVERSITY OF DEFENSE TECHNOLOGY PLA, 2016

A three-section wing design for unmanned aircraft that provides improved impact resistance and easy disassembly for transport. The wing uses a trapezoidal left and right section and a rectangular middle section. The sections are connected by a frame filled with foam and covered in carbon fiber composite skins. The sections are designed to have a trapezoidal cross-section for strength and lightweighting. The foam filling provides impact absorption. The sections can easily separate during impact to prevent damage to the aircraft's electronics. The electrical connections between the sections disengage automatically when the wing contacts the ground to protect the electronics.

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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