Drone
This custom-built drone features a 3D-printed frame designed in Fusion 360, reinforced with carbon fiber tubing for optimal strength-to-weight ratio. The motor mounts required multiple iterations to withstand vibrations, and I designed a custom adapter to securely attach propellers to motors. The landing gear uses carbon fiber with removable 3D-printed mounts for easy transport and repairs. A dedicated ESC holder keeps components organized and accessible. The build demonstrates iterative design through vibration analysis and structural optimization.
- Frame: 3D-printed + carbon fiber tubes
- CAD: Fusion 360
- Landing gear: CF tube w/ removable mounts
- Electronics: ESC, RX, custom mounts
Frame
The main frame is 3D-printed using Fusion 360 for design and optimization. The core structure weighs under one pound while maintaining structural integrity. Carbon fiber tubing forms the arms, providing exceptional durability and stiffness at minimal weight. To prevent tube rotation within the printed frame, I drilled holes and inserted anti-rotation screws that lock the tubes securely in place. This design balances weight reduction with structural rigidity for optimal flight performance.
Motor–Propeller Adapter
The original propellers were incompatible with the motor shafts, causing slippage during operation. I designed a custom adapter that bridges this compatibility gap with precise bore geometry and secure retention methods. The adapter features proper tolerances and clamping mechanisms to ensure reliable torque transfer from motor to propeller without slippage.
Motor Mounts (Iterative Design)
Motor mounts required extensive iteration due to vibration-induced failures during spool-up. Early designs cracked immediately under operational loads. The final design incorporates thicker walls, reinforced fillets at stress risers, and an anti-rotation pin that engages the carbon fiber tube. Screw bosses at motor attachment points provide additional reinforcement to prevent catastrophic failure during high-speed operation.
Landing Gear
The landing gear uses carbon fiber tubing for optimal strength-to-weight ratio. I designed a two-piece clamp system with top and bottom components secured by M3 screws. This removable design enables quick swapping for transport or repair scenarios. The system securely holds carbon fiber tubing while maintaining the lightweight advantages of the material.
ESC Holder & Wiring
The ESC (Electronic Speed Controller) requires connections to four motors, receiver, and battery, creating complex wire routing challenges. I designed a dedicated 3D-printed holder that organizes these connections while maintaining accessibility for troubleshooting. The design includes cable channels, service loops, and labeled leads to facilitate rapid diagnostics and maintenance while ensuring proper airflow around the ESC.
Problems and How I Overcame Them
- Vibration-induced failures: Early motor mounts cracked on spool-up. I increased wall thickness, added fillets at stress risers, and used an anti-rotation pin into the CF tube.
- Prop–motor incompatibility: Props slipped on the shaft. I designed a custom adapter with proper bore, keying, and clamping to lock torque transfer.
- Wire management and access: Dense ESC wiring made service difficult. I printed a dedicated holder, added cable channels, and labeled leads for fast diagnostics.
What I'd Build Next at Penn/MIT
I'd like to advance this platform into a more robust flight testbed—refining vibration isolation, closed-loop control, and modular payload mounts. I'm excited to collaborate on lightweight structures, control algorithms, and rapid iteration—from CAD to print to flight—to turn practical constraints into reliable, flying hardware.