This research investigates the factors affecting the thermoforming process for creating complex, lightweight components in the aerospace sector, especially for fixed-wing drones. Thermoforming, involving the heating of thermoplastic materials to shape them, is favored for its benefits like weight reduction, improved efficiency, and lower production costs. A critical factor is temperature, which must be carefully regulated to allow materials to reach their softening point without compromising their physical properties. Uncontrollable high temperatures risk excessive melting and degradation of these properties. Thus, using thermal simulation techniques and experimental analyses to optimize temperature is crucial. Additionally, the applied pressure during thermoforming significantly influences product surface quality and dimensional accuracy.



Choosing appropriate materials and combinations of thermoplastics is essential. For fixed-wing drones, lightweight, high-strength materials with good moldability, such as PVC, ABS, and polycarbonate, are ideal. The study also explores the effects of UV radiation in thermoforming, indicating that UV stabilizers can help maintain the mechanical and aesthetic characteristics of materials against UV exposure. The results show that optimizing temperature, pressure, and time enhances the quality and strength of the produced parts. This research offers valuable insights for the aerospace industry, improving the quality and performance of fixed-wing drones.