Polymer Micro-Lattice buffer structure Free Impact absorption

The uncrewed aerial systems industry is rapidly expanding due to advancements in smaller electronics, smarter sensors, advanced flight controllers, and embedded perception modules leveraging artificial intelligence. These technological progress have opened new indoor applications for UAS, including warehouse inventory management, security inspections of public spaces and facilities, and underground exploration. Despite the innovative designs from UAS manufacturers, there are no existing standards to ensure UAS and human safety in these environments. This study explores developing and evaluating micro-lattice structures for impact resistance in lightweight UAS. We examine patch designs using Face-Centered Cubic (FCC), Diamond (D), Kelvin (K), and Gyroid (GY) patterns and detail the processes for creating samples for impact and compression tests, including manufacturing and testing protocols. Our evaluation includes compression and impact tests to assess structural behavior, revealing the influence of geometry, compactness, and material properties. Diamond and Kelvin patterns were particularly effective in load distribution and energy absorption over the compression tests. Impact tests demonstrated significant differences in response between flexible and rigid materials, with flexible patches exhibiting superior energy dissipation and structural integrity under dynamic loading. The study provides a detailed analysis of specific energy absorption (SEA) and efficiency, offering insights into optimal micro-lattice structure designs for impact resistance in lightweight UAS applications.