Drone Design & 3D Print Project
Project Overview
Designed and built a quadrotor drone utilizing flight control and motors from a Zugo drone. Focussing on mechanical layout, structural integrity, and component integration. The project involved CAD modeling, hands-on fabrication, iterative testing, and performance evaluation.
Design Process
Concept → CAD → Prototype → Test → Refine
Step 1: Gather information of original drone (dimensions of components)
Step 2: Design a 3D model for each the top and bottom body
Step 3: 3D print prototype
Step 4: Test prototype and make modification/tolerancing
Step 5: Retest until achieved
Tools Used
Original Drone and Planning
Prototype #1
Prototype #2
Notes
Prototype #1: I began by creating two separate CAD models for the top and bottom body of the drone. Using Solidworks assembly I ensure both bodies lined up with correct tolerancing. After testing prototype #1 I noticed I need to fix tolerancing issues, include an area for the lights of the drone, making it symmetrical in both directions, and supports for the flight control board.
Prototype #2: After correcting these issues with prototype #1 I noticed a significantly better fit between the top and bottom bodies. Creating an area for the lights made the drone look more appealing. I did run into one problem, when putting prototype #2 together a motor wire sheared in half. I tried to solder the wire back together but there was not enough material to do so. Currently waiting for a replacement motor to test prototype #2.
Engineering Skills Demonstrated
Next Steps
Testing
Currently still working on my third prototype but had complication with a motor wire breaking. Waiting on parts.