This project report details the design, development, and construction of a quadcopter drone, undertaken as part of the ME5600B Advanced Manufacturing-II course. The project involved a comprehensive approach, beginning with the selection of electronic components such as motors, propellers, ESCs, flight controllers, batteries, and radio systems. The design phase focused on creating a robust frame, with initial designs evaluated using Finite Element Analysis (FEA) to assess structural integrity and material choices (PLA and ABS). The project then progressed to 3D printing the frame components, followed by the wiring and assembly of the electronic components. Iterative design updates were implemented, incorporating FEA to optimize the frame's design and exploring 3D printing with carbon fiber for enhanced strength. Further, the study investigated weight reduction techniques using 3-Matics software and lattice structures, with FEA used to validate the performance of the lightweight design. The final design, 3D printed and assembled, represents a culmination of the design process, including considerations for future improvements.
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