Abstract: The structural design and integral forming process of an ultra-short-range UAV were studied. The aramid fiber prepreg was used as the raw material of the outer skin of the UAV components, the glass fiber prepreg was used as the raw material of the internal load-bearing beam structure of the UAV components, and the self-expanding polyurethane foam core was used as the sandwich material of the UAV components and a pressurized material during internal expanding molding. The fuselage, wing, vertical tail and flat tail were successfully prepared using this molding process, verifying the feasibility of the overall molding process for UAV components. Static tests were conducted on the UAV components, and the UAV passed the static test. The structural design of the UAV was reasonable and met the strength design requirements.

Key words: UAV, composite, internal expanding forming, foam core, static test