Design and Implementation of a Low-Cost Folding-Wing UAV for Model Rocket Deployment

Rapid innovation in Uncrewed Aerial Vehicle (UAV) capabilities enable the opportunity for novel drone applications. Specifically, the growing use of UAVs in search-and-rescue, long-range surveys, and emergency deployment operations. Alongside developments in embedded electronic systems and rapid manufacturing methods, new opportunities are presented for integration of this technology into existing systems allowing for faster in-the-field manufacturing and rapid deployment solutions. Operational range and rapid deployment remain an obstacle in UAV technology as battery technology limits the search/survey area capable by a lightweight, field-deployed UAV and heavier long-range systems require significant launch infrastructure to facilitate deployment. Allowing the UAV to deploy from a higher altitude provides the opportunity for far greater range due to the gliding potential energy available to a fixed-wing UAV. Deploying at altitude also increases the efficiency of the system by removing the energy intensive climb process from the flight. Developing the UAV as a morphological fixed wing to fit within the payload of a small-scale rocketry system provides the opportunity to deploy at height, significantly increasing a UAV's range while maintaining a lightweight field-deployment capability. This paper details the design and development of a morphological fixed-wing UAV developed with sustainable principles to ensure low-cost, reusability, and ease of service. The system is developed using commercial off-the-shelf componentry (COTS) with most airframe components being 3D printed using PETG and LW-PLA filaments. All assembly is designed to be completed with adhesives and hand tools and employs a modular design allowing for different configuration options. The UAV employs a folding wing system deployed using elastic torque to transform the system from a stowed tubular assembly into a powered tractor configuration tandem wing. The system is developed with an emphasis on sustainability and future research by designing a significantly 3D printed airframe which allows for future development with new thermoplastic technologies. Developing the system to fit within any 4″ payload bay ensures compatibility with many rocketry systems. Scaled project deployment from a rocket successfully validates the deployment mechanism and versatility of the system as a payload. Uncontrolled hand-launched flight tests successfully demonstrate the aerodynamic capability of the aircraft in powered flight. The system successfully generates positive lift with high acceleration. Opportunity remains to integrate control surfaces and optimize aerodynamic and electrical efficiency before performing a full-scale test.