Rapid Prototyped Transition Fixed Wing VTOL Drone

Team: Mason Bush, Merrill Eggimann, Caleb Miller, Kathle Tischner

Sponsor: AggieAir

Project Description

  • Problem:
    • Airframe designed from US-sourced components, employing rapid prototyping to produce an inexpensive field ready and capable VTOL fixed wing drone.
  • Requirements and Constraints:
    • 15-pound gross takeoff weight (GTOW) with 1.5-pound payload capability (AgEagleAltum-PT).
    • 60-minute target flight time with 15-25 m/s cruise speed.
    • Includes standard AggieAiravionics (Orange Cube, radios, etc.).
    • Modular design which allows for field packability, assembly, storage, and repairability.
    • US-sourced design which allows for quick and inexpensive manufacturing.

Design Description

model on the floor
  • Wing: 3D printed modular sections with an Oratexskin
  • Fuselage: 3D printed with a removable skin
  • Tail: 3D printed with an OratexSkin
Design Description 1
Design Description 2
Design Description 3

Performance Review

Requirement / Constraint Target Threshold Predicted Performance Actual Performance
Gross Takeoff Weight (lb) 15 55 21.826 12.6
Supports Payload - Yes Yes Yes
Made in USA - Yes Yes Yes
Number of Components in Airframe 6 16 11 7
Hands-on Manufacturing Time (hr) 8 25 9.5 8
Time to Assemble Completed Airframe (min) 5 15 9.1 15
Packaging Dimensions (ft3) 1 5 2.9 -
Fixed-Wing Flight Time (min) 60 45 52.5 -
VTOL Flight Time (min) 5 3 3 -
Components Made In-House (%) 100 50 76.5 100
Airframe Cost ($) 250 1000 476.3 1300
performance review

Conclusion

  • Requirements Met:
    • Includes standard AggieAiravionics (Orange Cube, radios, etc.).
    • Modular design which allows for field packability, assembly, storage, and repairability.
    • US-sourced design which allows for quick and inexpensive manufacturing.
    • 15-pound gross takeoff weight (GTOW) with 1.5-pound payload capability.
  • Requirements Unmet:
    • 60-minute target flight time with 15-25 m/s cruise speed.
  • Lessons Learned:
    • Structural Considerations: Importance of wing structure.
    • Component Placement: Motor placement greatly affects center of gravity.
    • Material Selection: Long sections such as the wing are difficult for 3D prints to support.
  • Recommended Future Work:
    • Wing Strengthening: Address the torsional forces experienced by the center of the wing.
    • Pusher Motor Placement: Move the pusher motor forward.
    • Spar Sizing: Use a much larger spar for the VTOL spars.