UAV Drone
Type
Personal Project
Year
2025
I designed a Fixed Wing UAV Drone capable of flying 3 hours in the optimum conditions. This project was made to improve my skills in 3D modeling by using SolidWorks and analyze the efficiency of the drone by using CFD simulation in ANSYS Fluent.
This project was aimed to be built using 3D printing technology. When I first designed the UAV on paper, I had to choose between 3D printing or building it using wood and laser cutter. For the precision of manufacturing and the placement of each element inside the drone, I chose to be printed, and because it will take time and material, I have modeled more than 8 versions, different sizes, materials and thicknesses in different areas. The final version was thicker in areas where we need support for the battery, camera or servos (because of the momentum of the arm rotation), and thinner in other places (such as the top cover).
Another reason to choose 3D printing technology is the ease of use. For example, when the drone hits the ground or crashes into something mid-mission, all you need is to print the damaged part and assemble it after removing the old part from the body.
The parameters of printing, such as examples of the printed part, are shown in the following context.
For further information, and if you need the source design, reach out to me. I will be happy to help :)
Aerodynamic simulation
Aerodynamic simulation
Aerodynamic simulation
After finishing the first concept of the UAV i had to ensure the resuls and see the drag and lift forces, by using solidworks simulation right after the 3D modeling.
The results of the simulation were satisfying, found that the average value of the lift force was 30.6 N and the drag force 5.6N
After finishing the first concept of the UAV i had to ensure the resuls and see the drag and lift forces, by using solidworks simulation right after the 3D modeling.
The results of the simulation were satisfying, found that the average value of the lift force was 30.6 N and the drag force 5.6N
To make sure of the results i run another simulation in Ansys Fluent and the results were satisfying
To make sure of the results i run another simulation in Ansys Fluent and the results were satisfying
3D Modeling
3D Modeling
Designed specifically for additive manufacturing, this 3D-printed fixed-wing UAV features fully integrated structural and aerodynamic components, including optimized wings, winglets, and tail assemblies. To prevent wing flex during flight, the internal structure incorporates dual carbon fiber reinforcement tubes. Servo placements and protective covers were engineered based on proven commercial UAV layouts to ensure optimal weight distribution and control response. Additionally, the nose section features a custom bay sized for a 3000 mAh battery, with a uniform 2 mm wall thickness throughout the airframe for ideal structural integrity.
Designed specifically for additive manufacturing, this 3D-printed fixed-wing UAV features fully integrated structural and aerodynamic components, including optimized wings, winglets, and tail assemblies. To prevent wing flex during flight, the internal structure incorporates dual carbon fiber reinforcement tubes. Servo placements and protective covers were engineered based on proven commercial UAV layouts to ensure optimal weight distribution and control response. Additionally, the nose section features a custom bay sized for a 3000 mAh battery, with a uniform 2 mm wall thickness throughout the airframe for ideal structural integrity.
Servo placement
Servo placement
Servo Motors
Both servo motors were measured and integrated directly into the airframe structure. Dedicated mounting chambers were designed into each wing and tail section, as illustrated in the images below. Additionally, custom protective covers were implemented to eliminate the need for permanent adhesives, allowing for quick installation, secure retention, and easy field replacement.
Both servo motors were measured and integrated directly into the airframe structure. Dedicated mounting chambers were designed into each wing and tail section, as illustrated in the images below. Additionally, custom protective covers were implemented to eliminate the need for permanent adhesives, allowing for quick installation, secure retention, and easy field replacement.
Wing servo motor
Wing servo motor
Tail—servo placment
Tail-servo
Tail-servo
Access Hatch
Avionics Cover
For convenient access to internal electronics and the battery bay, I designed a simple bottom access hatch ready for prinitng, that features a built-in latch mechanism for easy opening and closing.
For convenient access to internal electronics and the battery bay, I designed a simple bottom ready for prinitng, that features a built-in latch mechanism for easy opening and closing.
Access hatch-top view
Access hatch-bottom view
Brushless Motor Support
Brushless Motor Support
The brushless motor was placed at the rear of the UAV in a pusher configuration for aerodynamic optimization and to calibrate the Center of Gravity (CG) near the mean aerodynamic chord. This counterbalances the front battery weight and internal electronics to ensure optimal longitudinal stability during flight.
As illustrated, the brushless motor is directly fastened to the rear support structure using mounting screws. A separate modular motor cowling(protective fairing) slides over the assembly to enclose the motor's sides and conceal the support mount, maintaining a streamlined aerodynamic contour. Once the cowling is secured in place, the propeller assembly is installed onto the motor shaft.
The brushless motor was placed at the rear of the UAV in a pusher configuration for aerodynamic optimization and to calibrate the Center of Gravity (CG) near the mean aerodynamic chord. This counterbalances the front battery weight and internal electronics to ensure optimal longitudinal stability during flight.
As illustrated, the brushless motor is directly fastened to the rear support structure using mounting screws. A separate modular motor cowling(protective fairing) slides over the assembly to enclose the motor's sides and conceal the support mount, maintaining a streamlined aerodynamic contour. Once the cowling is secured in place, the propeller assembly is installed onto the motor shaft.
What i have gained from this project
I have been working on this project for months. All that time, I have built more than 8 different versions, each one having its own good and bad design decisions. I have learned how to use SOLIDWORKS as someone who is building a project for marketing thinking through every decision regarding whether it is going to cost more or less material, whether it is worth it, and if there are any other solutions for that gap.
Honestly, I'm very proud to work on this project, challenging myself for a long time while seeing how I have improved. That improvement wasn't measured by days or weeks, but months. I saw the impact of practicing and rebuilding, especially in my team projects and when I passed the CSWP exam. I said to myself, "Well, that was easy," but it actually was never easy, it's just that I had already been through that difficulty a long time ago. Thank you for reading this.
I have been working on this project for months. All that time, I have built more than 8 different versions, each one having its own good and bad design decisions. I have learned how to use SOLIDWORKS as someone who is building a project for marketing thinking through every decision regarding whether it is going to cost more or less material, whether it is worth it, and if there are any other solutions for that gap.
Honestly, I'm very proud to work on this project, challenging myself for a long time while seeing how I have improved. That improvement wasn't measured by days or weeks, but months. I saw the impact of practicing and rebuilding, especially in my team projects and when I passed the CSWP exam. I said to myself, "Well, that was easy," but it actually was never easy, it's just that I had already been through that difficulty a long time ago. Thank you for reading this.
Aerodynamic simulation
Aerodynamic simulation
After finishing the first concept of the UAV i had to ensure the resuls and see the drag and lift forces, by using solidworks simulation right after the 3D modeling.
The results of the simulation were satisfying, found that the average value of the lift force was 30.6 N and the drag force 5.6N
To make sure of the results i run another simulation in Ansys Fluent and the results were satisfying
3D Modeling
3D Modeling
Designed specifically for additive manufacturing, this 3D-printed fixed-wing UAV features fully integrated structural and aerodynamic components, including optimized wings, winglets, and tail assemblies. To prevent wing flex during flight, the internal structure incorporates dual carbon fiber reinforcement tubes. Servo placements and protective covers were engineered based on proven commercial UAV layouts to ensure optimal weight distribution and control response. Additionally, the nose section features a custom bay sized for a 3000 mAh battery, with a uniform 2 mm wall thickness throughout the airframe for ideal structural integrity.
Servo placement
Servo Motors
Both servo motors were measured and integrated directly into the airframe structure. Dedicated mounting chambers were designed into each wing and tail section, as illustrated in the images below. Additionally, custom protective covers were implemented to eliminate the need for permanent adhesives, allowing for quick installation, secure retention, and easy field replacement.
Wing servo motor
Wing servo motor
Tail—servo placment
Tail-servo
Tail-servo
Access Hatch
Avionics Cover
For convenient access to internal electronics and the battery bay, I designed a simple bottom access hatch ready for prinitng, that features a built-in latch mechanism for easy opening and closing.
Access hatch-top view
Access hatch-bottom view
Brushless Motor Support
Brushless Motor Support
The brushless motor was placed at the rear of the UAV in a pusher configuration for aerodynamic optimization and to calibrate the Center of Gravity (CG) near the mean aerodynamic chord. This counterbalances the front battery weight and internal electronics to ensure optimal longitudinal stability during flight.
As illustrated, the brushless motor is directly fastened to the rear support structure using mounting screws. A separate modular motor cowling(protective fairing) slides over the assembly to enclose the motor's sides and conceal the support mount, maintaining a streamlined aerodynamic contour. Once the cowling is secured in place, the propeller assembly is installed onto the motor shaft.
What i have gained from this project
I have been working on this project for months. All that time, I have built more than 8 different versions, each one having its own good and bad design decisions. I have learned how to use SOLIDWORKS as someone who is building a project for marketing thinking through every decision regarding whether it is going to cost more or less material, whether it is worth it, and if there are any other solutions for that gap.
Honestly, I'm very proud to work on this project, challenging myself for a long time while seeing how I have improved. That improvement wasn't measured by days or weeks, but months. I saw the impact of practicing and rebuilding, especially in my team projects and when I passed the CSWP exam. I said to myself, "Well, that was easy," but it actually was never easy, it's just that I had already been through that difficulty a long time ago. Thank you for reading this.
