This project focuses on improving the design of a heavy-lift Y6 multirotor drone, specifically optimizing the frame based on an existing 1-inch square tube aluminum structure. The goal is to create a lighter, stronger, and more portable drone frame that can be quickly assembled, with an ultimate setup time of less than 10 minutes. Starting from the existing riveted aluminum design, we aim to refine and improve the frame’s performance, making it easier to transport and quicker to assemble.

We will begin by analyzing the current 1-inch square tube frame, identifying key areas where improvements can be made. The initial step involves assessing the strength, stiffness, and overall weight of the current frame. While the structure provides the necessary rigidity for a heavy-lift drone, it is not optimized for easy transport or quick setup. This analysis will serve as the foundation for a new, lightweight design that will still retain the necessary durability and strength.

Our redesign will incorporate a lattice structure into the frame, which will help reduce weight while maintaining strength. This lattice will be cut using CNC milling or water jet techniques, allowing us to fine-tune the design for weight optimization. The new structure will also focus on ease of assembly, ensuring that the drone can be broken down into sections that fit into a manageable container and can be reassembled on-site in less than 10 minutes. This is particularly important as we plan to scale the frame up in future iterations, so the ability to transport and assemble quickly is a priority.

Next, we will conduct a thorough structural analysis to balance the weight and strength of the tubes. Every component will be evaluated to determine the optimal design that minimizes weight without compromising integrity. Alongside this, we will tabulate the weight of each part, ensuring that we stay on track for an overall lighter frame. The target is to create a design that weighs significantly less than the current model, setting the stage for the future scaling of the drone.

To ensure the drone’s flight performance matches its structural improvements, we will use eCalc to simulate flight duration, power needs, and overall efficiency. This will help us select the right motors, propellers, and battery systems, ensuring the drone not only flies well but can handle heavy payloads with a longer flight time. The integration of these systems with the optimized frame will result in a much more efficient and capable design.

Once the design is finalized, we will fabricate a prototype using the optimized 1-inch square tube frame. This prototype will undergo rigorous testing to ensure it meets the desired weight, strength, and performance standards. After testing and making any necessary adjustments, the project will move into its next phase: scaling the design up.

In Spring 2024, we will scale up the frame to a 2-inch square tube structure. This larger version will be designed to carry even heavier payloads while maintaining the portability and ease of assembly achieved in the smaller version. The estimated weight for the scaled-up model is around 55 pounds, but our goal is to reduce that to 40 pounds or less, creating a lightweight yet robust structure. As with the smaller version, we will oversee the fabrication process and install all necessary components, including landing gear and brackets.

The ultimate vision for this project is to create a drone frame that is not only highly functional but also easy to transport, quick to set up, and capable of carrying heavy loads. By optimizing the current 1-inch frame and scaling up to a 2-inch version, we aim to develop a final design that significantly reduces weight while improving structural strength and flight performance.