Project Background

This project began in Spring 2021 as an assignment for my Sophomore Engineering Clinic, where students had to design a drone capable of completing an obstacle course and picking up a small payload. During this time, I developed a professional relationship with the instructor and the technologist, who lent their time towards developing the final project.

Despite the class formally ending that semester, I spent time over the summer to refine the design further for the coming semester. In the Fall 2021 semester, I began 3D printing the individual components using ABS and testing them accordingly. The final model, the Pioneer Quadcopter, was named so as it is my first drone design and truly a pioneer for my portfolio.

Spring 2021

Preliminary Design

This project first started out as an idea in my mind before appearing on paper for the first time.

SolidWorks Design

Drone Chassis

The drone chassis was the main body of the drone which featured mounting points for the flight controller and standoffs for the frame screws.

Drone Top

The drone top offered a finished surface for the frame screws to rest on and offered a few more millimeters of depth for the propellor ducts.

Drone Frame

The drone frame attached beneath the chassis and carried the battery and four motors.

First Printed Model

Aptly printed in gold PLA filament, this prototype allowed me to refine the design to fly.

Flight Model and Final Project Deliverable

The major design constraint of this entire project was the weight of the drone. After numerous changes to reduce weight, the final design completed the obstacle course and was submitted for a grade.

Fall 2021

For the fall semester, I was allowed to continue designing the drone without the original constraints that limited my creativity. With weight no longer a factor due to the inclusion of two batteries to drive the motors, I designed a more stable and solid drone using ABS plastic.

SolidWorks Design

Drone Chassis

Between the first and second design, the chassis didn't change much besides minor changes to the external walls.

Drone Top

With a stronger material, I was able to use thinner external walls that flexed during impact rather than breaking.

Drone Frame

The drone frame underwent the most design changes as the new drone now accommodated two batteries. There was also significant material added back to help with structure and limit breaks.

Landing Legs

The landing legs were by far one of the most important additions added to the new design. Unlike the previous iteration which used hex nuts that were friction fit into the PLA, this iteration had a nut built into the plastic using a z-stop on the 3D printer. The solid design allows the landing legs to take the most force and protect the more fragile arms of the frame.

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