This case study is focused on the development and structural optimisation of a drone propeller arm assembly under a typical operational load case. We highlight the powerful capabilities of MSC Apex Generative Design, which couples the power and ease of use of MSC Apex with the contemporary optimisation algorithms and geometry manipulation within Generative Design.

MSC Apex GD enables a radical new way of generating optimised geometry, which results in usable design geometry in a far reduced time frame over traditional topology optimisation techniques. 

Comparison with the original drone arm design yields an optimised structure with a 70% mass reduction, a ten-fold increase in stiffness and a doubling of component strength.

The full development process is broken down into a short overview and 4 narrated steps.

Case Study Overview

This overview gives an insight into the key features within MSC Apex Generative Design, and outlines the steps in the following videos.

Step 01: Design Model Assessment

This step is focused on the assessment of the original design model within MSC Apex Modeler/Structures, to yield a stress allowable for use in the subsequent MSC Apex Generative Design optimisation.

Step 02: Create Generative Design Model

This step is focused on the generation of design and non-design regions, loading, boundary cnoditions and materials within MSC Apex Generative Design.

Step 03: Generative Design Set-Up, Analysis and Output

This step is focused on the set-up, analysis and post-processed output within MSC Apex Generative Design.

Step 04: Model Verification and Assembly Interaction 

This step is focused on the FEA verification of the optimised structure within MSC Apex Modeler/Structures, along with the definition of the interactions within the original assembly.