Design of a 3D-Printed Modular Airframe with Interchangeable Vertical Stabilizers for Experimental Applications
Valeria VAVALÀ, Ambra GIOVANNELLI, Tomasz ⱢUSIAK
Abstract. The optimization of aircraft stability and aerodynamic performance is a key aspect of modern aerospace engineering, especially concerning vertical stabilizers, which are essential for maintaining yaw stability and controlling sideslip during flight. To enable adequate analysis regarding performance, stability, and control, a validated aerodynamic model of the aircraft has been created. The main goal of the study is to evaluate how stabilizer shape affects the aerodynamic traits of the airframe. In this paper it is examined a detailed view of the modular aircraft model, which was created, to ensure accurate and repeatable results, using computer-aided design (CAD) software and manufactured with fused deposition modelling (FDM) 3D printing using polylactic acid (PLA) material. This method provided a balance between strength and flexibility, allowing for precise reproduction of complex parts while reducing material waste. The modular design of the airframe enabled quick swapping of stabilizer components, making systematic and comparative analysis across different setups easier and ensuring consistent measurements under the same conditions. This research discusses the aerodynamic features of an aircraft model with modular, interchangeable vertical stabilizers set at different wedging angles. In total, there are seven pairs of easily replaceable elements. The model has been obtained in order to be used to perform tests in the wind tunnel. To sum up this research provides an airframe model construction and design traded off additive manufacturing effectiveness with attention to post-processing in order to create a solid experimental piece. Modular construction is an applied innovation that enables systematic aerodynamic performance investigation of vertical stabilizer effects.
Keywords
Aircraft, Gyroplane, Aerodynamic, 3D Printing, PLA Filament, FDM Technology, Modular Design, Vertical Stabilizers, Various Angles of Attack
Published online 7/20/2026, 6 pages
Copyright © 2026 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA
Citation: Valeria VAVALÀ, Ambra GIOVANNELLI, Tomasz ⱢUSIAK, Design of a 3D-Printed Modular Airframe with Interchangeable Vertical Stabilizers for Experimental Applications, Materials Research Proceedings, Vol. 69, pp 106-111, 2026
DOI: https://doi.org/10.21741/9781644904251-19
The article was published as article 19 of the book CEAS – AIDAA Conference 2025
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
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