About

Borders Full Size UAV Prototype

Goal: Design and build a prototype of the proposed DHS Borders design.
Solution: An advanced UAV system was designed and constructed, utilizing carbon-fiber composites, an advanced infra-red camera gimbal, and autopilot.

Tools

  • Catia v5r19
  • Surfcam
  • ANSYS
  • 3 & 5-Axis Mill

Design

External Design

We started the design around the fixed design elements of the request for proposals. This included the ducted power plant and the EO/IR camera gimbal. The twin boom design provided solid structure for the tail and mounting points for the duct.

Internal Structural Design

A composite skin over a more conventional structure was determined to be the best option to meet all requirements. The interior wood structures were designed to support the carbon fiber skin.

Transparent Skin View

Final Product

The final product was assembled and had vinyl stripes applied to aid in visibility in the air, as well as for asthetics. A base station was also assembled, providing downlinks for the UAV telemetry, control, and video from both onboard cameras.

UAV Front View

The final UAV has retractale landing gear, an EO/IR gimbal and full carbon fiber construction.

Base Station

The base station contained controls for the EO/IR gimbal and the autopilot. The central screen had a video stream from the nose camera on the aircraft. The laptop displayed data from the autopilot.

In Flight

The aircraft performed flawlessly in its test flights. All systems functioned nominally and video streams were clear from the base station.