2025 ASEE Annual Conference & Exposition

The undergraduate hands-on project presented herein is a testament to the interdisciplinary nature of our curriculum. It outlines the process of using reverse engineering techniques and CAD to model, simulate, and fabricate two drones in a senior project course. The project introduces students to the conceptual design of drones and the practical applications of CAD and simulation software to validate the drone's operational capability. In addition, students add mechanical and electrical components, GPS, a flight control unit, and a telemetry system to the existing drone so that it can be flown autonomously. This project serves as a comprehensive learning experience, allowing students to engage in redesigning, simulating, fabricating, and testing fully functional drones. The design process starts with using reverse engineering techniques to scan the parts, create 3D computer models, and implement minor necessary modifications to the fuselage and wing of the drones in CAD software and carry out simulation by selecting appropriate materials, propulsion systems, and flight controllers. After successfully modeling of drones in CAD, simulating, and validating the operational capabilities of the drone in CFD software, all airframe and wing parts are printed by a 3D printer. Students also gain hands-on experience in assembling the drone from individual components, such as the airframe, motors, propellers, and flight controller. In addition, they learn practical know-how of power distribution systems, wiring, assembling, and troubleshooting techniques. The other aspect of the project involves programming the drone's flight controller and onboard systems to communicate hardware with software. Finally, students conduct in-field flight operations of the drone to evaluate its stability and maneuverability. Students are required to develop a comprehensive project report and deliver presentations to showcase their achievements.

This project not only provides a platform for undergraduate students to acquire practical skills, foster interdisciplinary collaboration, and develop problem-solving abilities but also serves as a valuable introduction to the rapidly evolving field of drone technology.