Autonomous 3D-Printed Pacing Drone

Overview

I set out to build a large autonomous pacing aircraft that could execute programmed paths. The project combined airframe design, additive manufacturing, power electronics, flight-control integration, structural analysis, debugging, and outdoor test operations.

My contribution

I designed and fabricated the custom airframe, wired and integrated the electronics and propulsion system, configured ArduPilot and Mission Planner waypoint paths, and carried the vehicle through failure investigation and flight test.

Challenge

I needed the 3D-printed structure to support the loads, electronics, and propulsion system of a completed vehicle spanning roughly three feet from propeller tip to propeller tip and weighing about seven pounds fully assembled.

Technical approach

I used Fusion 360 finite-element analysis and spherical infill modifiers, which increased predicted arm strength by 17%. I integrated ArduPilot and Mission Planner, debugged a failed MOSFET, and iterated from bench work through programmed flight paths.