Polymer micro-lattice buffer structure free impact absorption

Advances in miniaturized electronics, perception modules, and flight controllers have expanded the use of uncrewed aerial systems (UAS) to indoor applications such as warehouse management, inspection, and subterranean exploration. Yet, no safety standards currently address the risks of lightweight aerial vehicles operating near humans. This study investigates ultra-light micro-lattice structures as protective elements to enhance crashworthiness without significantly affecting flight endurance. Patch samples with Face-Centered Cubic (FCC), Diamond (D), Kelvin (K), and Gyroid (GY) patterns were fabricated at an effective density of 65 kg/m3 and tested under compression and impact loading. Results show that Diamond and Kelvin lattices distribute loads more efficiently, achieving specific energy absorption values above 1000 J/kg, while impact tests reveal that flexible patches dissipate energy more effectively and maintain integrity under dynamic loading compared to rigid designs.