Improving Quality of 3D Printed Components for Remotely Piloted Aircraft Systems with Curved Layer Fused Filament Fabrication

The work in this thesis, explores methods of Additive Manufacturing applied to Remotely Piloted Aircraft Systems. The objective was to implement and test an alternate method of Fused Filament Fabrication using non-planar/curved layers. This was met by adapting a desktop 3D printer with an adapted nozzle and using a software offering non-planar layers. Both planar and non-planar prints were made to compare the strength using tensile and bend specimens. By completing flexural testing, it was determined that including non-planar layers did not provide a benefit to flexural strength with four or six non-planar top layers. Through printing different types of samples and angles, it was determined that using thicker layers and at low angles, non-planar printing provided improved surface quality. Recommendations for future work includes testing samples with different parameters, and improvements of printing hardware such as a custom printing nozzle or software.