Optimization of Different Materials for Drone Blades Using Computational Fluid Dynamics

Authors

  • Mustafa A. S. Mustafa Department of Refrigeration and Air Conditioning Engineering, Al-Rafidain University College, Baghdad, Iraq
  • Karar Saeed Mohammed Department of Medical Physics, Al Manara College for Medical Sciences, Maysan, Iraq
  • Hind Hussein Abbood Training and Workshop Center, University of Technology-Iraq, Baghdad, Iraq
  • Muhammad Asmail Eleiwi Electromechanical Engineering Department, College of Engineering, University of Samarra, Samarra, Iraq
  • Hasan Shakir Majdi Department of Chemical Engineering and Petroleum Industries, Al-Mustaqbal University College, Hillah, Babylon, Iraq
Volume: 15 | Issue: 4 | Pages: 25836-25843 | August 2025 | https://doi.org/10.48084/etasr.11430

Received: 12 April 2025 | Revised: 16 May 2025 | Accepted: 24 May 2025 | Online: 2 August 2025


Corresponding author: Muhammad Asmail Eleiwi

Abstract

This research utilizes Computational Fluid Dynamics (CFD) modeling to identify suitable materials for drone blades that present the best potential solutions. The primary objectives are the utilization of minimal resources and the implementation of lightweight construction methodologies to achieve optimal aerodynamic results. A distinct materials design strategy is employed in the blade's composition, with each component optimized for peak efficiency and performance. The modern aerial platform DJI Phantom 3 Pro was selected as the test platform due to its excellent capabilities and user-friendly interface. The original model of the DJI Mini 3 Pro drone was modified by printing its blades using an Anycubic printer that had 4K resolution and resin materials. An experimental procedure was designed to measure drone speed and maximum flight elevation after changing these newly designed blades The choice of blade material significantly influenced flight performance. The speed of drone flight is 34.9 km/h when using XMODEL15 blades, 18.4 km/h with Industrial ABS, and 15.3 km/h with ABS-Like blades. CFD simulations predicted a maximum air velocity of 3.716 m/s around the blades. Additionally, the XMODEL15 blades demonstrated the highest durability, enduring up to 118,750 cycles, whereas Industrial ABS achieved 90,655 cycles and ABS-Like achieved 70,384 cycles. These results confirm XMODEL15 as a superior material in terms of both aerodynamic performance and structural durability.

Keywords:

different materials, drone blade, CFD, DJI Phantom 3 Pro, 3D printing

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How to Cite

[1]
M. A. S. Mustafa, K. S. Mohammed, H. H. Abbood, M. A. Eleiwi, and H. S. Majdi, “Optimization of Different Materials for Drone Blades Using Computational Fluid Dynamics”, Eng. Technol. Appl. Sci. Res., vol. 15, no. 4, pp. 25836–25843, Aug. 2025.

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Copyright (c) 2025 Mustafa A. S. Mustafa, Karar Saeed Mohammed, Hind Hussein Abbood, Muhammad Asmail Eleiwi, Hasan Shakir Majdi

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