Client / Mission Context
Development and physical realization of a custom, reliable drone airframe to validate in-house rapid prototyping capabilities, component integration, and flight testing workflows for future scalable manufacturing and replication.
Problem / Requirement
Need for a light, customizable, and easily replicable drone system built from a proven European design.
Requirement to manage the complete lifecycle in-house—from additive manufacturing and electronics sourcing to final flight testing and documentation.
AVTS Role
Lead integrator and manufacturer across all phases: procurement of design assets, additive manufacturing, component selection, physical assembly, system calibration, and flight testing.
Equipment & Technology Used
Airframe Design: Sourced European drone airframe design.
Manufacturing: In-house 3D printers with custom-optimized print settings.
Avionics & Power: Flight controller, Electronic Speed Controllers (ESCs), brushless motors, and power distribution system.
Scope of Work
Design Procurement & Printing: Sourced the design assets and 3D printed the complete airframe using tuned in-house settings.
Component Integration: Sourced, fitted, and wired all mechanical and electronic sub-systems.
Assembly & Calibration: Built the physical unit and configured flight control parameters.
Testing Phase: Executed ground safety checks, system diagnostics, and multiple flight tests.
Documentation: Created a comprehensive build manual, configuration log, and test performance record.
Deliverables
Fully operational 3D-printed drone.
Complete component and assembly integration.
Full documentation package (build process, configuration settings, and flight test logs).
Result / Outcome
Successfully completed an end-to-end custom build cycle with proven flight stability and system reliability.
Established a standardized, documented blueprint for rapid replication, maintenance, and future iterations.
