CAD QC, Topology Optimization & Print Segmentation for 3D-Printable Fixed-Wing UAV

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.

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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.

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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)

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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.