This project was motivated by the goal of developing a compact, sub-250g quadcopter that maintains the high-speed performance of commercial 5-inch freestyle drones while remaining within legal weight limits. The design objective was to create a small form factor quad capable of flying through a standard window, allowing operation from indoors while preserving the immersive experience of FPV flight.
To begin, I established key design constraints:
- Total weight under 250 grams (including battery) to comply with FAA regulations.
- Motor-to-motor diagonal distance of 120 mm to ensure a compact footprint.
- Target top speed of at least 100 mph to match the performance of larger freestyle quads.
Next, I assembled and soldered all electronic components, followed by configuring the firmware and software stack. To enhance durability and vibration isolation, I designed a multi-piece 3D-printed canopy that channels impact forces into the frame and protects sensitive electronics and the gyro sensor.
Finally, I conducted PID tuning and filter optimization using black box log data to refine flight characteristics. The result is a lightweight, agile, and high-speed quadcopter that achieves professional-level performance while remaining fully legal and compact enough for convenient indoor operation.