Embedded Files
Unmanned Aerial System (UAS) Command, Launch, and Recovery Peripherals
Sponsored by Kurt Talke, Ph.D.
United States Naval Information Warfare Center Pacific (NIWC PAC)
Team 26
Parker Amano, Gregory Garner, Gabriel Lepage, and Bhodi Yohn
University of California, San Diego
Department of Mechanical and Aerospace Engineering
MAE 156B – Fundamental Principles Of Mechanical Design II – Spring 2025
Prof. Dr. Jerry Tustaniwskyj
Project Background and Needs Being Addressed
Project Background and Needs Being Addressed
Given the global proliferation of low-cost uncrewed aerial systems (UASs), their asymmetrical threat as demonstrated in current events (e.g., Ukraine and Israeli wars), and the forecasted funding within DoD, NIWC PAC UAS research areas need to focus on informed collaboration to channel innovation and demonstrate excellence in contribution to partnerships within Navy, across Joint Force and coalition partners to timely meet the evolving UxS need with sustainable tech transition from a recognized Center of Excellence.
To support this notion, we have developed a number of “government off the shelf” (GOTS), low cost multi-rotor and fixed wing UAS which are also NDAA compliant. Proprietary software licenses with commercially available "BLUE" UAS lead to non-refundable engineering costs, often pricing basic and applied R&D out, with a significant investment required just to get started. We have developed, and can provide as a launchpoint for new work, a low-cost open source, DoD approved capability to get in the air for ~$5k. As our systems have gained traction and are being used more, there is a need for some support peripherals:
Project Definitions and Functional Requirements
Project Definitions and Functional Requirements
Sub-Project I: Transport Case
Deliverables
Functional prototype of Transport Case
Design drawings
Bill of materials
Manufacturing and assembly instructions
Operation manual
Maintenance manual
Report documentation
Prototype Functional Requirements
Custom foam insert must hold:
Multirotor UAS
4 propellers
Jeti Duplex DS-12 controller
Isolates contents from unwanted jostling and vibrations
Waterproof external enclosure
Ergonomic loading/unloading of the UAS, propellers, and controller
Low-cost: below $600 per case
Reproducible for production in higher quantities
Sub-Project II: Ground Control Station
Deliverables
Functional prototype of Ground Control Station
Design drawings
Bill of materials
Manufacturing and assembly instructions
Operation manual
Maintenance manual
Report documentation
Prototype Functional Requirements
Small computer sufficiently powerful to run ArduPilot Mission Planner software
Three anti-glare 2500-nit monitors
Mechanical keyboard
Mouse/trackball
Speakers for audio
Bulkhead connections to case for all power and signal hookups
Six Ethernet ports
Six USB-A ports
Waterproof external enclosure
AC power cord and AC/DC brick
Sub-Project III: Pneumatic Launcher
Deliverables
Functional prototype of Pneumatic Launcher
Design drawings
Bill of materials
Manufacturing and assembly instructions
Operation manual
Maintenance manual
Analysis and testing data
Report documentation
Prototype Functional Requirements
Accelerates the fixed-wing UAS to a final launch speed of 13.5 m/s (30 mph)
Includes a regulator for consistent and adjustable launch power
Does not damage the UAS, internal payload, or rear propeller
Aimable within 10°-20° above horizontal
Can be assembled within 15 minutes.
Modular design that can be adjusted for compatibility with different drone wingspans
Man-portable, i.e., can be hauled in a truck bed
Sub-Project IV: Recovery Net
Deliverables
Technical design package (TDP) of Recovery Net, including:
Design drawings
Bill of materials
Manufacturing and assembly instructions
Operation manual
Maintenance manual
Analysis
Report documentation
Prototype Functional Requirements
Decelerates the fixed-wing UAS to a complete stop with no damage to the UAS, internal payload, or rear propeller
Minimum net width of double the UAS wingspan: 4 m
Minimum vertical net height of 2.5 m
Self-supporting all-metal frame construction
Cannot use PVC for frame construction
Cannot use stakes, sandbags, or guylines to support the frame
Must withstand being stepped on, left outside, and generally abused
Must be assembled and disassembled each within 10 minutes
Man-portable, i.e., can be hauled in a truck bed
Final Design Solutions
Final Design Solutions
Transport Case
Transport Case
Exterior Case: Chosen for its ideal size to efficiently transport the multirotor UAS, 4 propellers, and Jeti Duplex DS-12 controller, the exterior Pelican case provides a tough external shell resistant to impacts and crushing forces (Table 3.1, Figure 3.1).
Base Insert: The base insert cradles the required components in custom-designed slots to hold them still during transport.
Lid Insert: The lid insert provides additional padded support from above to reduce jostling of the required components inside the case.
Ground Control Station (GCS)
Ground Control Station (GCS)
The final Ground Control Station design consists of a Pelican 1700 Protector Long Case and an arrangement of integrated internally-housed electronics to facilitate seamless command workflows, superior pilot productivity, and enhanced information processing capability during drone missions with autonomous waypoint guidance and tracking (Figure 2.2). The Pelican case serves as a rigid waterproof enclosure around and structural foundation for the mounting hardware securing the electronic components.
Lenovo ThinkStation P3 Mini Computer: Powerful enough to run ArduPilot Mission Planner program smoothly and reliably.
1 TB storage
32 GB RAM
NVIDIA GPU chip
Logitech K845 Mechanical Keyboard: Provides comfortable, tactile feedback with a robust aluminum frame and dedicated numeric keypad.
Elecom Ergonomic Trackball Mouse: Enables seamless user interface and quick navigation across three screens, even on a constrained work surface.
Logitech Backup Mouse: Provides redundant control option in the case of trackball failure mid-flight.
TP-Link 8-Port Ethernet Switch: Enables linking to several different ground radios (Silvus, MicroHard).
Lenovo Docking Station: Enables productivity gains through additional monitor connections.
Lenovo USB Soundbar: Enables auditory alerts (‘beeps’ and ‘boops’) from flight control software to be heard.
Three Brytee Daytime Viewing Monitors: Three 2500-nit screens organize information spaciously and allow for clear, glare-free viewing even in direct sunlight.
StarboardⓇ HDPE: Lightweight, strong, durable, and UV-resistant 12.7 mm (0.5 in) thick high-density polyethylene used commonly in the marine electronics industry.
Lid Panel: Houses and protects monitor assembly inside lid of Pelican case.
Base Panel: Houses and protects mini computer, docking station, ethernet switch, and other electronics inside base of Pelican case.
Sub-Panel: Secured with nuts onto the bottom interior surface of the Pelican case via nine epoxy-bonded flathead screws, providing a modular
Pneumatic Launcher
Pneumatic Launcher
The final Pneumatic Launcher design consists of a high-pressure pneumatic system that accelerates a launch cart from which the fixed-wing UAS is launched. The pneumatic system is supported by a frame consisting of a main 8020 aluminum extrusion structural rail and two angled steel bipod feet. The rail serves as the guiding surface for the launch cart’s 8020-compatible linear slider, and hence sits at a launch angle aimable between 10°-20° above the horizontal (Figures 2.7, 2.8).
Pneumatic Power System: Stores and releases necessary energy content to accelerate the ~ 4 kg fixed-wing UAS to final launch speed of 13.5 m/s (30 mph).
Maddox Tire Bead Seater: Inexpensive, reliable, and commercially available tire bead seater acts as compressed air reservoir and energy source for launcher.
Butterfly Valve: Hand-operated valve provides rapid, low-loss release of pressurized air necessary for impulse delivery and launch cart acceleration.
PVC Air Tubing and Pressurized Barrel: 38.1 mm (1.5 in) inner diameter PVC Pipes rated to working pressures exceeding 20 bar (300 psi).
Pneumatic Piston: Delrin construction enables low-friction sliding through pressurized PVC barrel.
PVC Connections: Quick assembly and disassembly enabled through compression fittings.
Launcher Structure: Structurally efficient frame utilized shared component purposes to achieve smooth, usable rail surface at various launch angles.
8020 Aluminum Rail: Single 8020 aluminum extrusion acts as both main structural element and surface for compatible linear slider.
3-tiered rail provides modular, robust design.
Swiveling Steel Bipod Legs: Enable launch angle adjustment.
Pulley Train: Harnesses and transmits pneumatic forces from piston to launch cart, imparting desired acceleration to UAS.
3D-printed pulley from PLA roughly 16cm (6.25”) diameter
Launch cart accelerated via 5 mm DyneemaⓇ SK-78 cable (5400 lb load rating)
3D-printed cable feeder guides airflow for minimal losses
Custom aluminum cuts mount pulley to rail system
UAS-Compatible Launch Cart:
Linear Slider: 8020-compatible linear slider constructed from aluminum with self-lubricating UHMWPE inserts for low coefficient of sliding friction.
Dry Lubricant: WD-40 dry lubricant Further reduces frictional resistance hindering acceleration of launch cart.
Base Plate: Modular aluminum base plate design enables easy changes for payload testing, different airframes, etc.
UAS Mounts: Custom pivoting elements support and accelerate drone until impact, then swing down for easy release, avoiding damage to UAS empennage and propeller.
Forward Launch Ring: Ultra-strong steel anchor shackle swivels on aluminum cam and transmits launch acceleration forces onto reinforced carbon post underneath nose of UAS.
Rear Vertical Support Feet: 3D-printed feet on pivoting aluminum members support UAS fuselage at its center of mass (under wing spars).
Impact Attenuator: Diecast springs provide kinetic energy absorption at the end of the launch cart’s stroke length, with through-bolted fastening onto main aluminum rail for superior impact resistance.
Recovery Net
Recovery Net
The final Recovery Net design solution—submitted as a technical design package based on sponsor input and budget constraints—includes a frame built out of 8020 extruded aluminum, steel Unistrut scissor arms, adjustable bungee cords, nylon cables, and a custom net (Figure 2.9).
Extruded Aluminum Frame: Lightweight, strong, and corrosion-resistant; easily portable due to minimal fasteners and modular 8020 construction.
Quick Assembly and Disassembly: Few fasteners allow the frame to be packed down or set up quickly in the field.
Scissor Arm Mounting System: Arms are attached at 45° angles to the vertical 8020 posts using custom brackets and guides for consistent deployment.
Adjustable Bungee Attachment: Rear overhang on each scissor arm accommodates bungee cords, which stretch to absorb impact energy.
Energy Absorption: On impact, bungee cords extend (up to ~ 66 cm) causing the net to rotate back ~ 25°, safely decelerating the UAS [13].
Locking Mechanism: A safety catch locks the scissor arms post-impact to prevent rebound and secondary motion.
Elastic Nylon Net and Webbing: The net absorbs force via stretchable vertical nylon webbing straps, reducing shock on contact.
Load Distribution: Gaps between vertical struts allow the drone’s nose to pass through while its wings are caught, distributing the load across the entire net frame.
Design Videos
Page updated
Report abuse