Hardware

The Structures Team designs and fabricates the physical multirotor airframe and structural interfaces that support avionics and payload systems, with a focus on structural integrity, vibration management, and subsystem optimization. Using SolidWorks for CAD and in-house fabrication tools, the team develops airframes, motor mounts, and landing gear.

Additive and subtractive manufacturing methods are employed - including carbon fiber composites, reinforced filaments, CNC machining, and rapid prototyping - to maximize mechanical strength while reducing weight and flex. Designs are validated through load analysis and extensive testing in the Rutgers Aerospace Lab for PID tuning and fast iteration.

The Propulsion Team designs and integrates the thrust and power systems that define vehicle performance, focusing on sensors, wiring, power distribution, and autopilot integration. Using simulation tools alongside empirical testing, the team evaluates motor and propeller combinations, ESC integration, and battery configurations to ensure stable, efficient, and scalable flight across mission profiles. 

The team also ensures reliable communication throughout the electrical system while mitigating electrical noise between radios, flight controllers, ESCs, and motors. Thrust-to-weight ratio, thermal margins, efficiency curves, and endurance targets are evaluated throughout the design and validation process.