Project Objective:
The objective of this project was to design, build, and configure a fully functional 5-inch FPV drone from the ground up, integrating custom mechanical design with embedded electronics and flight control systems. Unlike conventional FPV drones that rely on commercially available carbon fiber frames, this project challenged me to develop a structurally sound frame and camera mount manufactured entirely through FDM 3D printing. A primary objective was to explore the limits of additive manufacturing in a high-performance application. The frame was designed to withstand the significant dynamic loads, impacts, and high-frequency vibrations generated during aggressive FPV flight while maintaining a lightweight, manufacturable design. This required careful consideration of structural load paths, print orientation, material selection, component placement, and vibration management to maximize durability and flight performance. Beyond the mechanical design, the project provided hands-on experience integrating and soldering the drone's electronic systems, configuring the flight controller and peripherals, and calibrating the aircraft using the INAV flight control software. Through this process, I gained practical experience in system integration, electronics, sensor calibration, and flight controller configuration while developing an understanding of how mechanical design and control systems influence one another. An equally important objective was to create the project as an open-source platform that could be easily reproduced and improved by the maker community. The frame was intentionally designed with manufacturability, modularity, and ease of assembly as key design requirements. Components were engineered to print with minimal support material where possible, disassemble easily for maintenance or repairs, and accommodate future modifications without requiring a complete redesign. By emphasizing accessibility alongside performance, the project was intended to provide a customizable platform that anyone with access to a 3D printer could manufacture, adapt to their own needs, and continue developing. Ultimately, this project served as both a challenging mechanical design exercise and an introduction to the complete development process of autonomous and remotely piloted aircraft. The knowledge and experience gained through this project provide a strong foundation for more advanced UAV and robotics projects.
The design process began with a series of concept sketches created in a digital sketching app called Procreate on an iPad. These sketches were used to rapidly explore different frame geometries, motor layouts, and overall proportions before committing to a detailed CAD model. Working digitally allowed ideas to be generated and refined quickly while evaluating factors such as structural symmetry, component placement, and the overall appearance of the aircraft. Once a concept was selected, the sketch was imported into Autodesk Fusion 360 and used as a reference to establish the overall frame geometry. The design then evolved from a simple structural layout into a complete digital assembly by incorporating each electronic component and ensuring adequate space for wiring, fasteners, and maintenance. Throughout the design process, component placement was determined by both structural and electrical considerations. The GPS and compass module was positioned as far as practical from the high-current motor and ESC wiring to reduce electromagnetic interference while maintaining an unobstructed upward view of the sky for reliable satellite reception. The battery was mounted above the rear of the frame to counterbalance the weight of the forward-mounted camera system and extended front arms, resulting in a more balanced center of gravity. Mounting the battery on top of the frame also provides additional protection during hard landings. After the primary layout was finalized, the remaining structural and functional features were incorporated into the design, including mounting provisions for all electronics, ventilation openings for improved airflow, hardware retention features, and a removable belly pan. The belly pan was designed to house the FPV camera system while providing quick access for maintenance. By removing only the belly pan and disconnecting a single cable, the camera assembly can be serviced independently, while simultaneously exposing the flight controller, ESC, and internal wiring for convenient inspection and repairs. The final stage focused on validating the design through physical prototyping. Individual components were 3D printed and assembled to verify fitment, tolerances, and overall manufacturability. Test prints identified areas requiring refinement, allowing adjustments to be made to mating features, hardware clearances, and print tolerances before proceeding to subsequent iterations. This iterative approach allowed structural weak points and assembly challenges to be identified early in the development process, resulting in a design that was easier to manufacture, assemble, maintain, and modify while remaining consistent with the project's goals of modularity and open-source accessibility.
The frame was designed to maximize structural rigidity while remaining easy to manufacture through FDM 3D printing. The entire frame is printed as a single-piece component, eliminating the need for mechanical joints or interlocking sections that would otherwise require manufacturing tolerances and could introduce unwanted play or additional failure points. To further optimize manufacturability, the frame is oriented to print flat on its top surface, allowing it to be produced without support material. This reduces material consumption, shortens print time, and minimizes post-processing while improving the quality of the finished part. The arm geometry was designed to balance flight performance with manufacturing constraints. The front arms extend farther outward than the rear arms, increasing the distance between the propellers and the FPV camera to minimize propeller intrusion into the camera's field of view during flight. In contrast, the rear arms are positioned slightly closer together so the complete frame fits within the build volume of a standard 256 mm × 256 mm desktop 3D printer, making the design accessible to a wide range of users without requiring larger-format equipment. The underside of the frame serves as a protected electronics bay, housing critical components such as the flight controller (FC) and electronic speed controller (ESC). Positioning these components within the frame shields them from direct impacts during crashes or hard landings while maintaining a compact and organized internal layout that simplifies wiring and maintenance.
The belly pan was designed as a modular camera system that integrates the FPV camera, video transmitter (VTX), and VTX antennas into a single removable assembly. Rather than mounting each component independently throughout the frame, all camera-related electronics are consolidated onto the belly pan, creating a compact and organized module that simplifies both assembly and maintenance. A primary design objective was to maximize serviceability. The entire camera module can be removed by extracting four mounting screws and disconnecting a single electrical connector, allowing the complete assembly to be detached in one piece. This exposes the internal electronics bay, providing unobstructed access to the flight controller, ESC, wiring, and other onboard components without requiring the camera system to be disassembled. The modular approach also simplifies cable management by keeping the camera and video transmission wiring contained within a single removable assembly. The belly pan also incorporates an adjustable camera mount, allowing the FPV camera angle to be easily tuned to match different flying styles. Pilots can increase the camera angle for faster, more aggressive flight or decrease it for slower, more precise maneuvering without modifying the frame itself. To further improve image quality, the camera mount is supported by two vibration-isolating pads that reduce the transmission of high-frequency vibrations from the airframe to the camera. By damping these small oscillations, the isolation system helps produce smoother FPV footage and minimizes vibration-induced artifacts during flight.
Thermal management was an important consideration throughout the design process to ensure reliable operation of the drone's electronic systems during demanding flight conditions. The frame utilizes a passive open-air cooling architecture, with strategically placed ventilation openings surrounding the flight controller (FC), electronic speed controller (ESC), and video transmitter (VTX). This promotes continuous airflow through the electronics bay, helping dissipate heat generated during sustained high-power operation, particularly during aggressive acrobatic (Acro) flight and prolonged high-speed maneuvers. Special attention was given to the video transmitter (VTX), as these components are particularly susceptible to overheating due to their high power density. In addition to the VTX's integrated cooling fan and heat sink, it is mounted in an open section of the frame where airflow is largely unrestricted. Ventilation openings positioned above, below, and on both sides of the transmitter allow air to circulate freely around the component, maximizing passive cooling while the aircraft is in flight. To further improve thermal performance, a forward-facing air scoop is integrated directly above the VTX cooling fan. During forward flight and rapid climbs, the scoop directs outside air toward the VTX, increasing the amount of cooling airflow reaching the heat sink and fan assembly. This combination of passive ventilation, directed airflow, and active cooling helps maintain lower operating temperatures, improving the reliability and longevity of the onboard electronics under demanding flight conditions.
Frame Material: PA12-CF (Carbon Fiber Reinforced Nylon) *can be constructed from standard PLA*
Flight Controller Software: INAV
Motor Size: 2306
Motor KV Rating: 2450KV
Propeller Size: 5-inch
Battery: 4s 100c 1500mAh Lipo
Estimated Hover Time: TBD
GPS Module: M10 GPS + Compass
Position Accuracy: ~1.5m
FPV Camera: 1080p 100fps
VTX Frequency: 5.8 GHz
Radio Receiver: ExpressLRS 2.4 GHz
Overall Weight (without battery): 516g
Overall Weight (with battery): 680g
Assembly Method: Modular screw-fastened construction for easy maintenance and upgrades
Primary Manufacturing Process: FDM Additive Manufacturing on Bambulabs X1C
The frame and structural components were optimized for FDM manufacturing using PA12-CF filament and configured to maximize structural performance while maintaining a practical balance between strength, stiffness, weight, and print time. The walls were printed using three wall loops to increase wall thickness, improving impact resistance and allowing the outer shell to carry a greater portion of the structural load. Both the top and bottom surfaces were printed with five solid layers, creating a rigid outer skin that significantly increases bending stiffness while providing durable exterior surfaces. An adaptive cubic infill pattern was selected at 15% density to provide efficient support in all three dimensions while minimizing unnecessary weight. To further improve internal rigidity, the infill was printed using two-fill multiline passes, producing thicker internal members that increase stiffness compared to a standard single-line infill. The material selected for this project was PA12-CF, chosen for its excellent strength-to-weight ratio, toughness, ease of printing, dimensional stability, and superior impact resistance compared to many common FDM materials. These properties make it well suited for applications subjected to the repeated impacts and vibration experienced during FPV flight. All remaining print parameters were left at the default PA12-CF profile in Bambu Studio. All TPU components were printed at default settings.