Topology-Optimized Drone Bracket
A motor bracket 41% lighter than the machined original — simulated, printed in carbon nylon, and flight-tested in 11 days.
Overview
A commercial drone maker needed to shed grams without losing stiffness. Their machined aluminum bracket was strong but heavy, and every gram cut directly into flight time. Voxelcrest reimagined the part for additive: topology optimization removed material where loads were low, and carbon-filled nylon replaced aluminum where stiffness mattered most.
The Challenge
Vibration, crash loads, and motor heat ruled out basic plastics. The bracket had to survive a 2-meter drop test, hold motor alignment within 0.1 mm under thrust, and dissipate heat — all while weighing under 90 grams.
Our Approach
We ran FEA load simulations on three lattice strategies, printed the winner in PA6-CF carbon nylon, and validated with torque, vibration, and drop testing. Two iterations refined rib placement before the final flight article shipped with a full dimensional report.
41% lighter
than the machined aluminum original, with equal stiffness.
11 days
from first simulation to flight-tested article, reports included.
Zero rework
on mating interfaces — motor alignment held under full thrust.
