Carbon Fiber Sub-250g FPV Quad Copter
I set out to design and build a 3-inch FPV quadcopter capable of rivaling standard 5-inch quads in performance while maintaining a total weight under 250 grams, making it legal to fly without FAA certification. I designed a custom carbon fiber frame and performed Finite Element Analysis (FEA).
The...
Mechanical design and 3D modeling in SolidWorksFinite Element Analysis (FEA) for structural validationDesign for manufacturability (DFM) using waterjet cuttingStress and impact simulation under crash conditionsFactor of safety optimization for lightweight structuresAerodynamic and weight optimization for UAV performanceTolerance analysis and mechanical fitment testingSolidWorks (3D CAD modeling, assemblies, FEA)Betaflight configuration and tuningBlackbox log analysis for flight performance evaluationESC and flight controller firmware setupWaterjet machining of carbon fiber compositesCarbon fiber layup and material handling techniquesPrecision soldering and electronics assemblyWire routing and PCB fitment testing3D printing (TPU and structural materials) for protective componentsRapid prototyping and iteration of UAV partsIterative design and testing under real-world conditionsRoot cause analysis of mechanical and electrical failures