We designed the mechanical structure for a lightweight fixed-wing UAV, with the primary objective of maximising structural efficiency while minimising total airframe weight. Reducing structural mass directly extends flight endurance and increases available payload capacity, making weight-optimised design a core engineering requirement for this project.

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The airframe layout was developed in 3D CAD, with load paths from the propulsion system, wing roots, and landing interface points all accounted for in the structural design. Material selection focused on lightweight aluminium alloys in primary load-bearing sections, combined with lighter materials in non-structural areas. Component geometry was optimised to remove material from low-stress regions while reinforcing high-load connection points such as motor mounts and wing attachment interfaces.

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Structural validation confirmed the design meets flight load and landing impact requirements within specified safety margins. The client received complete CAD files and manufacturing drawings ready for production, together with documentation of the structural analysis supporting each design decision.