Iterative development of a custom high-speed drone

The goal was to develop a compact, high-performance drone as a complete system – from the mechanical design and material choice to component integration and a flight-capable prototype.

I designed the complete body in Onshape and manufactured it using 3D printing. The first version used PA-CF and was assembled with the selected electronics into a functional prototype.

• Complete custom CAD design in Onshape
• Additive manufacturing of the body in PA-CF
• Mechanical and electronic system integration
• Flight testing of the first prototype

Practical testing revealed three central areas for improvement: vibration, component cooling and weight distribution. The PA-CF body also showed moisture-related changes in flexibility over time. These findings became requirements for the second revision rather than being hidden as isolated defects.

The revised design is intended to address the findings systematically. ABS-CF is planned as the new body material, while the component layout and cooling concept are being reworked. Weight distribution is also being improved before FPV hardware is integrated and the next test series begins.

• Planned switch from PA-CF to ABS-CF
• Improved component cooling
• Revised weight distribution
• FPV integration after mechanical validation

The first version is a flight-capable prototype, but not yet the final FPV system. Its greatest value is the verified design feedback it produced. Weight, flight time and top speed will be added only after they have been measured under defined test conditions.