A Multi-Criteria Decision Model for Preliminary Selection of UAV Outer-Shell Material Architectures

Abstract

In this study a standards-guided multi-criteria decision analysis (MCDA) model is developed for preliminary screening of UAV outer-shell material architectures. It categorizes printable skins, short- and continuous-fiber reinforcement, composite laminates, local metallic features and cellular crash absorbers and tests them against 12 mechanicals, impact, vibration, environmental, thermal/fire, RF, manufacturing, repair and lifecycle criteria. Scores are treated as auditable engineering screening values rather than experimental measurements; their provenance is classified using E1-E4 evidence-traceability levels. Reference and mission-specific weights are evaluated using deterministic sensitivity analysis and a reproducible Monte Carlo procedure. Numerical recalculation confirms the reference ranking: PETG-CF lattice 3.758/5, CFF carbon-nylon 3.550/5, and PETG/ABS honeycomb hybrid 3.500/5. Under alternative missions, CFF carbon-nylon leads the stiffness/load-path case, PETG/ABS honeycomb leads the RF-sensitive enclosure case, and Al 6061-T6 leads the thermal/fire-constrained case. PETG-CF lattice is first in 95.03% of 20,000 base-case Monte Carlo trials and 81.64% in a conservative evidence-class uncertainty stress test. The results are preliminary screening outcomes, not qualification claims. The PETG-CF lattice is an architecture class rather than a fixed geometry; full coupon-, panel-, shell-, RF-, fire-, environmental-, modal-, FEA-, and lifecycle validation is required before design release.