Hardware

Structures designs and fabricates the multirotor airframe and structural interfaces that support avionics and payload systems. 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.

Propulsion designs and integrates the thrust and power systems that define vehicle performance. Using simulation tools such as eCalc alongside empirical testing, the team evaluates motor and propeller combinations, ESC integration, and battery configurations to ensure stable and scalable flight across mission profiles. Thrust-to-weight ratio, thermal margins, efficiency curves, and endurance targets are all considered throughout the design and validation process.