Design and Multi-Faceted Validation of UAV Arm Clamps, Landing Gear and Motor Mounts via Generative Design in Autodesk Fusion 360

The reliability of the entire airframe is essential for Unmanned Aerial Vehicles (UAVs) deployed in critical surveillance and disaster management missions. Performance cannot be compromised, as even minor structural weaknesses can impact flight stability and mission success. This work introduces a thorough "design–simulate–build–test" process that combines advanced simulation, additive manufacturing, AI-driven generative design, and experimental validation to construct an assembly of high-performance UAV structural components. Motor mounts, arm clamps and landing gear were among the important structural components of a custom UAV that were redesigned using the suggested technique. With the use of Autodesk Fusion 360's generative design tools, every component was tailored for Fused Filament Fabrication (FFF) additive manufacturing. Their mechanical performance was first predicted through a detailed Finite Element Analysis (FEA) framework. To experimentally validate these simulations, both generatively designed and conventionally designed counterparts were 3D printed using PLA+ and subjected to controlled mechanical strength tests. Results demonstrated a strong correlation between simulated predictions and experimental outcomes. The generatively designed components consistently outperformed their baseline counterparts, exhibiting significantly higher stiffness (eg. a 29.6% reduction in displacement for the arm clamp), improved dynamic stability, and greater load-bearing capacity. These enhancements were achieved without any measurable increase in mass, confirming the efficiency of the optimized geometries. This study establishes a comprehensive, end-to-end framework for designing and validating structurally optimized UAV components through experimental verification. By enhancing multiple airframe subsystems, the research delivers a unified advancement in overall airframe reliability, structural resilience, and mission robustness for UAV deployments in challenging operational conditions.