Abstract
<jats:p>The current trend in aircraft structural design is to use composite materials as primary structural elements. The main objective of the project is to design the parts as per ASTM standards by using CATIA V5R21 software and develop Rapid prototyping based composites with adequate structural integrity for subsequent use of Mini Unmanned Air Vehicles. In the present work, an attempt is made on RP technology especially Fused Deposition Modeling (FDM)to make aerodynamic body parts or airframe structures either hollow or porous and its superior properties which in turn would help in weight reduction with enhanced strength, corrosion and fatigue resistant and to build accurately to design specifications. In the present work, ABS (acrylonitrile-butadiene styrene), plastic is electroplated with copper (Cu) and Nickel (Ni) electrolytic solutions. The coating thickness of Cu and Ni layer approximates to 5µm, 35µmand 55µm respectively. These coated samples are subjected to FEM analysis to make a note of increase or decrease in the mechanical strength (Tensile, Flexural, Compression, Impact and Hardness). Analysis is processed on two different types of sample specimens by ANSYS software. The obtained results are compared with the uncoated samples. The result of the simulation indicates that coating bestows an increase in strength to the ABS samples.</jats:p>