Enhancing Drone Endurance in Sub-Zero Environments via Multi-Modal Bio-Chemical Approaches

Abstract

Unmanned aerial vehicles operating in sub-zero environments face two major challenges that limit their mission endurance: ice accumulation on propeller surfaces [1, 2] and battery performance degradation[3]. While active heating systems can address these issues, they impose significant weight and power penalties that reduce i operational ability. This study presents an integrated approach combining a penguin-feather inspired propeller design [4, 5] with phase-change material thermal management [6, 7, 8] to enhance drone endurance in extremely cold conditions.

We have developed two coupled surrogate models: one that captures propeller icing dynamics through impingement(of ice) and freezing behavior [9, 10], and another that models battery thermal response with embedded phase-change materials. Unlike previous studies that examine aerodynamic or thermal performance separately, our model calibrates both parameters together under realistic flight conditions through a Monte-Carlo simulation. The penguin-inspired surface modification uses natural ice-shedding mechanisms observed in Spheniscus humboldti (penguin) [4], while strategically placed phase-change materials delay temperature caused battery degradation.

Monte-Carlo Simulation results across five hundred randomized scenarios demonstrated a mission success probability of 0.89 for the bio-inspired configuration, compared to a substantially lower baseline performance. Battery thermal simulations showcased a clear performance hierarchy, with the hybrid phase-change material and chemical heater configuration providing optimal endurance. Computational fluid dynamics validation in ANSYS confirmed reduced ice adhesion on the modified propeller surface, with ice mass accumulation visibly lower than conventional propellers.

These findings establish a practical, lightweight framework for cold-weather drone deployment in rescue, delivery, and scientific applications [11, 12].