Purpose: The purpose of this paper is to present the preliminary design of a medium altitude long endurance (MALE) unmanned aerial vehicle (UAV), focusing on the interaction between the aerodynamic and the structural design studies. Design/methodology/approach: The classic layout theory was used, adjusted for the needs of unmanned aircraft, including aerodynamic calculations, presizing methods and CFD, to estimate key aerodynamic and stability coefficients. Considering the structural aspects, a combination of layout, finite element methods and custom parameterized design tools were used, allowing automatic reshapes of the skin and the internal structural parts, which are mainly made of composite materials. Interaction loops were defined between the aforementioned studies to optimize the performance of the aerial vehicle, maximize the aerodynamic efficiency and reduce the structural weight. Findings: The complete design procedure of a UAV is shown, starting from the final stages of conceptual design, up to the point where the detail design and mechanical drawings initiated. Practical implications: This paper presents a complete view of a design study of a MALE UAV, which was successfully constructed and flight-tested. Originality/value: This study presents a complete, synergetic approach between the configuration layout, aerodynamic and structural aspects of a MALE UAV.

Generative design is a design method inspired by nature’s evolution, pushing the limits of the industry to new design solutions. Using minimum input requirements, the resulting designs can be structurally adequate, weight-optimised and almost production-ready. The main purpose of this paper is to present the different approaches of the standard engineering design and the generative design methods. This is achieved through the case study of a nose landing gear for a prototype tactical unmanned aerial vehicle, intended for low volume production. The first part of the paper outlines the conceptual design of the nose landing gear. Subsequently, during the preliminary phase, the stress distribution along the different parts is calculated, based on the classic Strength of Materials theory and therefore a design solution is produced. In the second part, a generative design study is carried out with a commercially available tool, based on the conceptual parameters previously chosen. Both concepts are studied with industry-standard finite element analysis tools in order to validate, from a theoretical standpoint, the strength requirements according to the STANAG 4671 regulation. The final structure will be manufactured with 3-axis CNC machining, while providing about 36% weight reduction without compromising the structural functionality.