Ultra-Lightweight UAV: 2nd Year Aerospace Design Project

About Us

We are a small, dedicated group of second-year Astronautics and Aerospace Engineering students at the University of Southampton. As part of our core design modules, we are tasked with engineering a high-performance, ultra-lightweight drone from the ground up. While we aren't a massive, heavily funded university club, we are incredibly passionate about applying our coursework in theoretical aerodynamics and structural optimization to build a real-world, highly functional prototype.

The Project: High-Durability Quadcopter

Our major assignment involves the complete design, analysis, and fabrication of a custom multirotor. A primary focus of our build is extreme weight reduction without compromising structural integrity.

Through extensive FEA (Finite Element Analysis) in SolidWorks, we have engineered a specialized "sandwich" style central frame. As seen in our CAD files, the main body utilizes an intricate honeycomb hex-pattern cut-out. This geometry significantly reduces the overall weight while maintaining the torsional stiffness required for flight. We have also designed a custom spring-loaded suspension landing gear system to protect the onboard electronics and payload during hard landings.

Our Need for CNC Machining

While we have optimized our design digitally, manufacturing this frame on a strict student budget is our biggest hurdle. To achieve the specific weight-to-strength ratio required by our assignment rubric, the main chassis must be constructed from carbon fiber.

Because of the complex honeycomb patterns and the tight tolerances needed for the arm mounts and suspension joints, cutting this raw material by hand in our student workshops is impossible. We need professional CNC machining for our carbon fiber plates to ensure the sandwich structure aligns perfectly and functions safely.

Why We Need PCBWay's Support

Sourcing precision-machined carbon fiber is currently out of reach for our group's personal budget. PCBWay’s support would be a massive help in bringing our CAD model to life and allowing us to physically test our engineering calculations.

In exchange for your sponsorship, we would proudly feature PCBWay’s logo on the drone itself and highlight your brand's contribution during our final assessed presentations in front of our professors and university cohort. We will also provide PCBWay with high-definition photos and videos of the final assembled drone in flight for your marketing team to use. Your support will directly help a small group of aspiring aerospace engineers turn a digital concept into reality.