Experimental FPV / Autonomous UAV

Project Overview

This project is an experimental FPV-capable autonomous UAV designed as a self-directed engineering challenge. The objective was to design and integrate a complete system from first principles, without relying on build guides or tutorials, using manufacturer datasheets and specifications as primary references.

The platform is based on ArduPilot and Mission Planner, providing full autonomous capability (GPS, barometer, IMU, compass) while retaining manual and acro flight modes. It features a custom-built 12S LiPo power system, low-KV motors driving 15-inch carbon fiber propellers, DroneCAN ESCs, and extensive custom mechanical integration.

All CAD, 3D-printed components, wiring layouts, battery construction, and mechanical modifications were designed and fabricated in-house. The aircraft is currently in a pre-flight integration phase, with bench power-up and motor spin validation underway.

Motivation & Approach

• Challenge to design and integrate a UAV entirely independently, without tutorials or step-by-step guides.
• Hands-on learning of high-power electrical systems, avionics, and UAV flight stack integration.
• Practical experience with CAD, 3D printing, mechanical modification, and custom fabrication.

System Architecture

• Frame: Carbon fiber, slight modifications for installation of electronics
• Power System: Custom 12S 10000mAh LiPo configuration, 120C rating, 10AWG wiring.
• Motors & Propellers: 235KV motors, 15-inch carbon fiber props, 7.5 pitch.
• ESCs: DroneCAN controlled, 120A rated, custom mounts.
• Flight Controller: Matek Slim H743 V4 running ArduPilot.
• Receiver: SBUS for initial testing; full integration pending.
• VTX & Camera: Analog 1W VTX with stock antenna; camera selected for FPV integration.
• Logging: MicroSD blackbox logging; full telemetry pending flight.

Current Status

- Bench power-up and motor spin validation in progress (propellers removed).
- System has not yet flown; landing gear and full outdoor testing remain to be completed.
- Flight controller data readings (GPS, Compass, etc...) all functional and accurate.
- Receiver can not send proper SBUS signal to flight controller.
- ESP8266 under consideration for wireless flight controller adjustments.
- Landing Gear Design/Prototyping in progress.
- Possible GoPro mount rework.

Next Steps

• Install sbus converter from receiver to flight controller.
• Complete bench motor testing with low-throttle verification and temperature checks.
• Design and 3D-print PETG-CF landing gear.
• Perform full flight testing, logging, and data analysis.
• Install and weight/impact test landing gear

Notes & Lessons Learned

• Incremental testing is critical for high-power UAV builds.
• Hands-on fabrication and integration improve understanding of system-level dependencies.
• Bench validation and proper labeling of system status help prevent misinterpretation of project readiness.
• Gained experience in new 3D-Printing filament types inlcluding PETG, PETG-CF.
• Gained experience with unconventional 3D-Printing methods.