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3D-Printable Fixed-Wing UAV Airframe — CAD Quality Control & Print Optimization I have an existing CAD design for a 3D-printable fixed-wing UAV. The airframe has already been designed and segmented into approximately 14 sections for a Bambu Lab printer (256 × 256 mm bed). I am looking for a CAD engineer to QC the files and optimize them for printing. IMPORTANT: All optimizations must preserve the existing aerodynamic geometry. Outer mold lines are not to be modified unless pre-approved. --- Scope of Work: 1. Structural Analysis, Weight & Material Optimization - Perform stress analysis based on expected aerodynamic and inertial forces during flight to identify high- and low-load regions. - Apply topology optimization and/or generative design to internal structures to reduce filament usage and weight without compromising structural integrity. - Identify and hollow out any unnecessarily solid sections. - Maintain load-bearing capacity around spar channels, motor mounts, and payload bay. - Recommend filament material per section based on structural load. - Identify areas that would benefit from carbon fiber tube inserts or carbon fiber filament reinforcement, and specify location, diameter, and length. - Optimize internal geometry to reduce print time (infill zones, bridging, perimeter count). - Recommend print orientation per section to minimize supports and maximize layer strength along primary load paths. 2. Segmentation & Joint Refinement - The airframe is segmented into ~14 sections sized for a 256 × 256 mm Bambu Lab print bed. - Redesign all segment interfaces for a clean, natural, self-locating fit — minimize or eliminate the need for glue. - Add interlocking features where appropriate: lips, offsets, male/female extrusions, alignment pins, or press-fit interfaces. - Design joints to allow partial disassembly and individual section replacement without disturbing the rest of the airframe. - Confirm every segment fits within the 256 × 256 mm bed footprint. 3. DFM Review & Fuselage Clean-Up - Evaluate and improve the fuselage geometry for visual and aerodynamic cleanliness. - Flag and resolve any other Design for Manufacturing (DFM) issues identified during review. --- Deliverables: - Native CAD files (Fusion 360 preferred; SolidWorks or STEP also acceptable) - Optimized, print-ready STL files organized by section - Detailed change log covering: - What was changed and why - Stress analysis summary with load map - Print orientation recommendation per section - Material recommendation per section (PLA / PETG / ABS) - Carbon fiber reinforcement recommendations (location, spec, and purpose) --- Ideal Candidate: - Proficient in topology optimization and stress analysis tools (Fusion 360 Simulation & Generative Design, nTopology, Altair Inspire, or similar) - Strong FDM design-for-manufacturing experience - Experience designing interlocking and segmented 3D-printed assemblies - Aerospace, UAV, or RC aircraft design background strongly preferred To be considered, please include examples of previous related work — aerodynamic or UAV/RC airframe projects are strongly preferred, topology optimization or segmented print assemblies also relevant.

Project ID: 40410802