Abstract

This study examines the effect of small ply angle deviations on the structural response of carbon fiber-reinforced polymer laminates representative of structures used in unmanned aerial vehicles (UAVs). A combined experimental and numerical approach was applied, including cantilever bending tests and experimental modal analysis, supported by finite element simulations. Laminates with nominal ply orientations of 0°, 5°, and 10° were manufactured using a manual hand lay-up process to reflect typical production variability. The results show that the numerical model accurately captures the observed trends in both bending deformation and natural frequencies, with discrepancies up to 12.5%. A consistent tendency to slightly overestimate stiffness was observed, leading to lower predicted deflections and higher natural frequencies compared to experimental data. The findings confirm that finite element modeling can reliably detect and predict the structural effects of small fiber misalignment, supporting its use in the assessment and design of lightweight composite structures used in UAV applications.

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