Integrated technical framework for lightweight UAV design, composite manufacturing, and predictive reliability support in civil aviation

Abstract

Modern unmanned aerial vehicle (UAV) development can no longer be treated as a purely aerodynamic exercise; it depends on the coordinated handling of materials, manufacturing, aerodynamics, energy use, and in-service reliability. This paper develops a literature-based technical framework that links material selection, computer-aided configuration design, curing control of polymer composite parts, vacuum infusion manufacturing, computational fluid dynamics (CFD) evaluation, and predictive maintenance into a single engineering cycle. The synthesis draws on recent studies of V95P alloy wire behavior, automated UAV appearance design, curing of thick-walled composite components, multifunctional composite UAV design, and predictive maintenance of aircraft engines, supported by wider literature on composite aerostructures, resin infusion, energy management, and aircraft prognostics. The resulting five-layer model is intended as a methodological basis for UAV prototyping, aviation engineering education, and civil aviation research, rather than as an experimentally validated design.