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Design and Manufacturing Innovations in Modular Drone Design Enabled by Additive Manufacturing: Customizable Power Distribution Board

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Conference

2023 ASEE Annual Conference & Exposition

Location

Baltimore , Maryland

Publication Date

June 25, 2023

Start Date

June 25, 2023

End Date

June 28, 2023

Conference Session

Manufacturing Workforce Development

Tagged Division

Manufacturing Division (MFG)

Tagged Topic

Diversity

Page Count

15

DOI

10.18260/1-2--42927

Permanent URL

https://strategy.asee.org/42927

Download Count

280

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Paper Authors

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Firas Akasheh Tuskegee University

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Dr. Akasheh has been with the Mechanical Engineering Department at Tuskegee University since 2008. His primary interest is in the area of solid mechanics and manufacturing as well as the integration of best practices in engineering education.

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Stephen Baker

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Mandoye Ndoye Tuskegee University

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Mandoye Ndoye received the B.S.E.E. degree from the Rensselear Polytechnic Institute, Troy, NY, in 2002, the MS degree in Mathematics and the Ph.D. degree in electrical and computer engineering from Purdue University, West Lafayette, IN, in 2010. After co

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David Shannon Auburn University

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Dr. Shannon has a Ph.D. in Educational Research and Evaluation Methodology and Statistics from the University of Virginia and is currently the Humana-Sherman-Germany Distinguished Professor at AU. He teachers courses in research methods and program evalua

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josiah e blocus Tuskegee University

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Eugene Thompson

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Abstract

Additive manufacturing (AM) is a relatively recent development in manufacturing which represents a paradigm shift in the way parts are made. Creating parts layer by layer offers many benefits including the ability to create parts with high level of geometric complexity, while forgoing the need for molds and dies, vertical integration of design and manufacturing activities, and the facilitation of customization even at mass. In the area of product development those benefits make design iterations fast and inexpensive, which not only translate into shorter development cycle, but also empower engineers to innovate in way not possible before. In a preceding work, we showed how interdisciplinary team of students developing a modular quadcopter drone ideated, built, and tested several innovative concepts, all of which were enabled by AM. In this work, we extend the preliminary work on the development of a concept for a customizable 3D printed power distribution board to replace a typical commercially available PDB which will further support additional innovations in modularity and improved functionality. The students designed the board, built it using FDM 3D printing, and tested it under maximum load conditions to ensure its proper functioning without excessive heating. Preliminary testing showed that, within the normal operating time before battery recharging becomes necessary, the board’s temperature increases by about 18 oF, which is acceptable. As a final step in the pursuit of this concept, the board was integrated into the drone body and a procedure for embedding the electric wiring was developed. This integration required several design modifications, which were implemented and prototyped. We believe that this modular drone development project design and mentorship guided by the principles of experiential learning and empowered by AM has increased the efficacy of students and helped them develop several skills that are valuable to the future engineering work force including team skills, leadership, time-management, life-long and interdisciplinary learning, and entrepreneurship mindset. Through a survey and focus group approach, the findings of an independent evaluator confirm those benefits to the students participating in the project.

Akasheh, F., & Baker, S., & Ndoye, M., & Shannon, D., & blocus, J. E., & Thompson, E. (2023, June), Design and Manufacturing Innovations in Modular Drone Design Enabled by Additive Manufacturing: Customizable Power Distribution Board Paper presented at 2023 ASEE Annual Conference & Exposition, Baltimore , Maryland. 10.18260/1-2--42927

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