In our research, we focused on optimizing PC/ABS composites for drone technology applications, particularly for structural components such as fuselage supports and wing connectors. The increasing demand for lightweight, high-performance materials in drone technology requires balancing thermal stability, mechanical strength, and oxidation resistance under prolonged exposure to high-altitude thermal and oxygen-rich environments. We systematically investigated the effects of PC/ABS mass ratio and synergistic additives—graphene (GN), antioxidant 1010, organic phosphorus flame retardant (OP), and UV absorber UV-327—on the composite’s properties. All samples were prepared through a process of drying, mixing, extrusion granulation, and injection molding. The optimal formulation was then validated on 1:5 scaled drone structural parts.
1. Effect of PC/ABS Mass Ratio on Drone Technology Composite Performance
We first varied the PC content from 0% to 100% by mass while keeping total polymer mass constant. The key mechanical and thermal properties are summarized in Table 1. The tensile strength increased rapidly with PC content up to about 60% PC, after which the rate of increase diminished due to interfacial crazing at higher PC concentrations. The impact strength peaked at 18.7 kJ/m² when the PC/ABS ratio was 60/40, indicating optimal crack termination by the ABS phase. The heat deflection temperature (HDT) reached 118 °C at this ratio, sufficient for typical drone parking lot exposure up to 70 °C. The Rockwell hardness (R-scale) was 121, and density was 1.15±0.02 g/cm³, meeting both rigidity and lightweight requirements for drone technology.
| PC mass fraction / % | Tensile strength / MPa | Impact strength / (kJ·m⁻²) | Heat deflection temperature / °C | Rockwell hardness (R-scale) | Density / (g·cm⁻³) |
|---|---|---|---|---|---|
| 0 | 42 | 14.2 | 88 | 89 | 1.05 ± 0.02 |
| 20 | 53 | 16.1 | 95 | 98 | 1.08 ± 0.02 |
| 40 | 64 | 17.5 | 106 | 110 | 1.12 ± 0.02 |
| 60 | 78 | 18.7 | 118 | 121 | 1.15 ± 0.02 |
| 80 | 83 | 15.1 | 124 | 127 | 1.18 ± 0.02 |
| 100 | 85 | 10.8 | 130 | 130 | 1.20 ± 0.02 |
Based on these results, we selected the 60/40 (PC/ABS) mass ratio as the baseline for further additive studies, as it provided the best overall balance for drone technology structural applications.
2. Influence of Additives on Thermal Stability and Oxidation Resistance for Drone Technology
We incorporated various additives into the 60/40 PC/ABS base: 0.5 phr GN, 1.0 phr OP, 2.0 phr antioxidant 1010, and 0.3 phr UV-327, both individually and in combinations. The oxidative induction time (OIT) was measured at 200 °C under oxygen flow. Table 2 shows the OIT values. Adding antioxidant 1010 alone increased OIT by 49.5% compared to the neat composite. The best synergistic effect was observed with GN + antioxidant 1010, achieving an OIT of 48.3 min, a 69.5% improvement over the unmodified material. This enhancement is critical for drone technology operating under long-duration high-altitude thermal-oxidative conditions.
| Additive system | OIT / min | Improvement over neat / % |
|---|---|---|
| None | 28.5 | — |
| Antioxidant 1010 (2 phr) | 42.6 | 49.5 |
| GN (0.5 phr) + Antioxidant 1010 (2 phr) | 48.3 | 69.5 |
| GN (0.5 phr) + OP (1 phr) | 41.2 | 44.6 |
| GN (0.5 phr) + UV-327 (0.3 phr) | 35.1 | 23.2 |
| OP (1 phr) | 33.8 | 18.6 |
| UV-327 (0.3 phr) | 31.2 | 9.5 |
We also analyzed the thermogravimetric (TG) and derivative thermogravimetric (DTG) curves for selected formulations. The initial decomposition temperature (T5%) and char residue at 800 °C are summarized in Table 3. The GN + OP combination gave the highest T5% (about 410 °C) and char residue (18.2%), indicating improved thermal stability through a synergistic barrier effect. The maximum degradation rate temperature was delayed to approximately 480 °C with a peak rate as low as 18 %/min, demonstrating reduced thermal degradation kinetics.
| Additive system | T5% / °C | Char residue at 800 °C / % | Tmax / °C | Peak degradation rate / (%·min⁻¹) |
|---|---|---|---|---|
| None | 365 | 8.5 | 445 | 28 |
| GN + OP | 410 | 18.2 | 480 | 18 |
| Antioxidant 1010 + UV-327 | 390 | 10.3 | 460 | 24 |
| GN + Antioxidant 1010 | 395 | 12.1 | 465 | 22 |
Thermal conductivity was another critical factor for drone technology, as heat dissipation prevents local hot spots. Table 4 shows that the GN + antioxidant 1010 system gave the highest thermal conductivity: 0.31±0.02 W/(m·K) at 25 °C and 0.35±0.02 W/(m·K) at 80 °C. This indicates efficient heat transfer capability, beneficial for drone components exposed to direct sunlight or motor-generated heat.
| Additive system | Thermal conductivity at 25 °C / [W·(m·K)⁻¹] | Thermal conductivity at 80 °C / [W·(m·K)⁻¹] |
|---|---|---|
| None | 0.22 ± 0.01 | 0.25 ± 0.01 |
| GN (0.5 phr) | 0.26 ± 0.01 | 0.30 ± 0.01 |
| Antioxidant 1010 (2 phr) | 0.24 ± 0.01 | 0.27 ± 0.01 |
| GN + Antioxidant 1010 | 0.31 ± 0.02 | 0.35 ± 0.02 |
| GN + OP | 0.29 ± 0.01 | 0.32 ± 0.01 |
| GN + UV-327 | 0.28 ± 0.01 | 0.31 ± 0.01 |
3. Long-Term Thermal-Oxidative Aging Performance for Drone Technology
We subjected the optimized 60/40 PC/ABS with GN (0.5 phr) + antioxidant 1010 (2 phr) to accelerated aging at 80 °C, 50% RH, and 21% O2 for up to 168 h. The tensile strength retention after aging is shown in Table 5. Even after 168 h, the composite retained more than 86% of its initial tensile strength, demonstrating excellent oxidation resistance. In contrast, the unmodified composite retained only about 62% under the same conditions. This high retention is essential for drone technology reliability during repeated flight cycles and extended outdoor storage.
| Aging time / h | Tensile strength / MPa | Retention / % |
|---|---|---|
| 0 | 78.0 | 100.0 |
| 24 | 75.5 | 96.8 |
| 48 | 73.2 | 93.8 |
| 72 | 70.8 | 90.8 |
| 168 | 67.1 | 86.0 |
4. Validation on Drone Structural Components
We injection-molded 1:5 scaled drone fuselage supports and wing connectors using the optimal formulation (60/40 PC/ABS + 0.5 phr GN + 2.0 phr antioxidant 1010). The molded parts exhibited defect-free surfaces and consistent dimensions. We performed a 10-cycle thermal shock test (−10 °C to +70 °C, 2 h per cycle) followed by a static load test simulating a 1.5 kg drone payload. No cracking or deformation was observed, confirming the practical viability of the composite for drone technology applications.
5. Conclusion
Our study demonstrated that a PC/ABS mass ratio of 60/40 provides the best mechanical and thermal performance for drone technology structural parts. The synergistic addition of 0.5 phr graphene and 2.0 phr antioxidant 1010 significantly improved oxidative induction time by 69.5%, thermal conductivity by about 41%, and long-term thermal-oxidative strength retention above 86%. The thermal stability, as evidenced by TG/DTG and HDT data, meets the demands of high-temperature drone operation. These findings offer a practical material solution for enhancing the reliability and service life of drones in complex environments, promoting the wider adoption of PC/ABS composites in drone technology.