3D‑Printable Long‑Range FPV Drone Airplane Design (5 kg Additional Payload)
Budget: £250 – £750 GBP
Project Overview
We need an experienced CAD/aerodynamics engineer to create a modular, 3D‑printable fixed‑wing FPV drone airframe capable of carrying an extra 5 kg of payload in addition to its own fully‑assembled weight (including avionics, batteries, structural reinforcements, etc.). The design must deliver long‑range endurance and be optimized for high cruise speed given FDM‑printable materials.
Key Objectives
5 kg Extra Payload Capacity: Airframe engineered to support ≥5 kg of external payload mounted on top, beyond the plane’s own weight (airframe + avionics + battery).
Long‑Range Endurance: Target ≥2 hours flight time or ≥100 km range on a single battery pack.
High‑Speed Performance: Aerodynamically refined wing and fuselage shapes to maximize lift‑to‑drag at cruise speeds.
3D‑Printable Modularity: Printable sections (wings, fuselage, tail) with integrated guide‑pin locators and self‑aligning pegs.
Reinforcement Integration: Internal channels for carbon‑fiber spars, composite rods, or foam cores to maintain rigidity under load.
Comprehensive Documentation: Full parts list, BOM with suppliers, print‑settings guide, and step‑by‑step assembly manual.
Scope of Work
Preliminary Study & Aerodynamic Analysis
Sketches and 3D concept models illustrating payload mounting.
Lift/drag and weight‑power trade‑off analysis to confirm range/endurance with 5 kg extra payload.
Parametric CAD Design
Create native CAD (SolidWorks, Fusion 360, etc.) featuring:
Detachable wings, fuselage modules, and tailbooms
Guide‑pin holes, alignment pegs, and snap‑fit features for effortless assembly
Reinforcement cavities sized for standard carbon‑fiber spars
Export STEP and print‑ready STL files for every module.
Structural Verification & Payload Testing
Calculate strength and factor of safety under full‑load conditions (airframe + batteries + avionics + 5 kg payload).
Ensure minimal flex and reliable structural margins during maneuvers.
Performance & Range Report
Estimate cruise speed, stall speed, maximum range, and endurance based on selected motor, propeller, and battery specs.
Printing & Assembly Guidelines
BOM listing recommended filaments (e.g. PETG, Nylon), electronics (motors, servos, avionics), fasteners, and reinforcement materials.
Print‑orientation advice, infill percentages, support strategies, and post‑print finishing tips.
Illustrated PDF assembly manual with exploded‑view diagrams and reinforcement placement.
We need an experienced CAD/aerodynamics engineer to create a modular, 3D‑printable fixed‑wing FPV drone airframe capable of carrying an extra 5 kg of payload in addition to its own fully‑assembled weight (including avionics, batteries, structural reinforcements, etc.). The design must deliver long‑range endurance and be optimized for high cruise speed given FDM‑printable materials.
Key Objectives
5 kg Extra Payload Capacity: Airframe engineered to support ≥5 kg of external payload mounted on top, beyond the plane’s own weight (airframe + avionics + battery).
Long‑Range Endurance: Target ≥2 hours flight time or ≥100 km range on a single battery pack.
High‑Speed Performance: Aerodynamically refined wing and fuselage shapes to maximize lift‑to‑drag at cruise speeds.
3D‑Printable Modularity: Printable sections (wings, fuselage, tail) with integrated guide‑pin locators and self‑aligning pegs.
Reinforcement Integration: Internal channels for carbon‑fiber spars, composite rods, or foam cores to maintain rigidity under load.
Comprehensive Documentation: Full parts list, BOM with suppliers, print‑settings guide, and step‑by‑step assembly manual.
Scope of Work
Preliminary Study & Aerodynamic Analysis
Sketches and 3D concept models illustrating payload mounting.
Lift/drag and weight‑power trade‑off analysis to confirm range/endurance with 5 kg extra payload.
Parametric CAD Design
Create native CAD (SolidWorks, Fusion 360, etc.) featuring:
Detachable wings, fuselage modules, and tailbooms
Guide‑pin holes, alignment pegs, and snap‑fit features for effortless assembly
Reinforcement cavities sized for standard carbon‑fiber spars
Export STEP and print‑ready STL files for every module.
Structural Verification & Payload Testing
Calculate strength and factor of safety under full‑load conditions (airframe + batteries + avionics + 5 kg payload).
Ensure minimal flex and reliable structural margins during maneuvers.
Performance & Range Report
Estimate cruise speed, stall speed, maximum range, and endurance based on selected motor, propeller, and battery specs.
Printing & Assembly Guidelines
BOM listing recommended filaments (e.g. PETG, Nylon), electronics (motors, servos, avionics), fasteners, and reinforcement materials.
Print‑orientation advice, infill percentages, support strategies, and post‑print finishing tips.
Illustrated PDF assembly manual with exploded‑view diagrams and reinforcement placement.