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DESIGN AND FABRICATION OF 3D PRINTED DRONE CONTROLLED BY PHONE

(PROJECT PHOENIX)

Article · September 2022

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PROJECT PHOENIX 2021-22

DESIGN AND FABRICATION OF 3D PRINTED DRONE

CONTROLLED BY PHONE (PROJECT PHOENIX)

Prithvi G
Student, Department of Mechanical Engineering, Vidyavardhaka College of
Engineering (2018-2022)

ABSTRACT

This project presents the design and fabrication of a multi-rotor drone also known as a
Quad-copter which is completely designed by using 3D printers involving usage of
certain 3D materials like Polylactic Acid (PLA), Elastomeric Polyurethane Resin
(EPU) and Thermoplastic Polyurethane (TPU). The technical uniqueness of this
project is that it can work in dual controlled manner, the drone can either be
controlled by the conventional radio controller and also by tracking the movement of
the phone.

The software used to create a 3D CAD model for this project is SOLIDWORKS 2019
and the configuration software used to calibrate the drone is the “Clean flight
controller” along with “Beta flight controller”. This project has helped me to
understand the working of drone and drone principles in the most helpful manner as it
has provided me an hands on experience on building a drone from scratch.

The usage of technologies like Additive manufacturing has proved to be of great help
in iterative trials and manufacturing the components in short amount of time and
highest geometric accuracy.
Keywords: 3D printed drone, NAZE 32, Quadcopter, DIY drones

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1. INTRODUCTION

In the present industrial revolution in aerospace sectors/industries drones are the most
common technology which is used worldwide either in the military purpose or even
for common man usage some even use drones as an hobby. Unmanned Aerial Vehicle
(UAV) commonly known as Drones is an aircraft without any human passengers or
crew members on board the aircraft. UAV come under a division of Unmanned
Aircraft Systems (UAS) which includes a ground-based controller and a system of
communication.

This project alias “Project Phoenix” works by using the basic principle of quad-copter
with 4 motors and a pair of motors spinning in clockwise direction and other pair of
rotors spinning in counter clockwise direction.
The Bluetooth mode of control allows the drone to be controlled up to a certain range,
as this model is still in the prototype stage allowing room for advancements for future
modifications

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2. TYPES OF DRONES

While designing a drone it is important to understand the classification and

characteristic feature of each type of drones. Four types of drones are considered and
discussed: multi-rotor, single-rotor, fixed-wing and fixed-wing hybrid.

2.1.1 MULTI-ROTOR CONFIGURATION

A quadcopter is generally though of when thinking of UAV. Typically it is driven by

four rotors, where the direct opposite rotors spin in the opposite direction. This type of
UAV is the easiest to engineer, since as long as the rotors are spaced in a symmetrical
way it will fly without problems. Stability and flexibility are two of the main
advantages of a quadcopter; it can suspend itself in the air and take photos from a still
position. Furthermore, it can move very flexibly, in any direction at any given time,
which may prevent crashes in tightly packed neighbourhoods. Finally it will not need
a lot of space for take-off since it can take-off vertically.

Advantages Disadvantages
Easy to engineer Less energy efficient
Take still photos Photos while moving changes camera
angle
Flexible movements Can be fragile
Possible to add solar panels Low payload capacity

Table 2.1: Advantages & Disadvantages of Quadcopter

Fig 2.1: Quadcopter (Multi-rotor configuration)

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2.1.2 SINGLE ROTOR CONFIGURATION

A single-rotor, or helicopter, type of UAV is contrary to the fact that it is called a

single-rotor type, two rotors. These rotors consist of a large rotor and a smaller, tail
rotor. These types of UAVs are much more efficient than it’s multi-rotor counterpart,
but still less efficient than a fixed-wing.

Fig 2.2: Single rotor configuration

2.1.3 FIXED-WING CONFIGURATION

Fixed-wing type UAVs are entirely different in build and using purposes. Where rotor
types are able to suspend themselves in mid-air, fixed-wing UAVs are constantly
moving at a certain horizontal speed. They remain at altitude by the lift force
generated by the wings, which counteracts the gravitational force. This way, it moves
in a more efficient way than a rotor type UAV. This, and the fact that it is always
moving, is why it is very suitable for long distance operations, such as mapping. The
main disadvantage of a fixed-wing solution is that it is less flexible in moving around
mid-air and needs either a runway (a small grass field is usually enough) or some sort
of launching base to propel it into the air.

Advantages Disadvantages
More energy efficient No photos from still position / cannot
suspend in mid-air
Constant angle while moving (at equal Only suitable area for solar panels is on

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altitude) the wings

More robust shape Needs a runway or launching mechanism
Higher payload

Table 2.2: Advantages & Disadvantages of Fixed-wing

Fig 2.3: Fixed-wing configuration

2.1.4 FIXED-WING HYBRID CONFIGURATION

The final type researched is a fixed-wing hybrid UAV. This type of UAV has VTOL
(Vertical Take-Off and Landing) capabilities and can take-off and land vertically as
the name suggests, while in the air flies like a fixedwing UAV. With this design the
aim is to combine the benefits of a multi-rotor with the flying efficiency of a
fixed-wing UAV. However this leads to a complex design and a bigger chance of
complications during flying.

Fig 2.4: Fixed-wing hybrid configuration

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2.2 SELECTION OF UAV

When it comes to selecting a UAV configuration to work there are some important
criteria that play a really important criteria in selecting the configuration. The table
below (Table 1.3) explains about the criteria required to be met for the selection
process. Careful considerations had to be made in choosing the type of drone to be
built and finalized upon building a quadcopter.

Features Factor UAV Multi-rotor Fixed-wing Single-rotor Fixed-wing

Type hybrid
Range Short Long Variable Long

Speed Limited Variable Variable Variable

Efficiency low High Medium Medium

General Specs
Flight time 20-30 min Couple of Higher than Higher than
hours multi-rotor multi-rotor
Payload Small Medium High Variable
Capacity
Camera control High Medium High High

Runaway VTOL Yes VTOL VTOL

Skill training Easy Medium Easy Easy

Controllability
Controllability Easy Medium Easy Easy

Maintain Average Average Average Average

Altitude
Maintenance Not often Not often Often Often
Robustness Waterproof Casing Casing Casing Casing

Shockproof Casing Casing Casing Casing

Changing Yes Yes Yes Yes

casing
PV cells Not easy Easy Low Low
Adjustability Change in High Low Low Low

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efficiency

Rotor High Medium High Medium

adjustments
Risk of use Possible Possible Yes Possible

Easy to Medium Yes Medium No

Other simulate
Costs Low Medium High High

Table 2.3: UAV Type selection

3. PHYSICS BEHIND DRONES

3.1 Forces acting on a drone

Fig 3.1: Physics behind drones

For a UAV there are four principle forces that affect how they fly namely, weight, lift,
thrust, drag.
a. Weight - Weight is the force of gravity. It acts in downward direction towards
the center of the Earth.
b. Lift - The force that acts at right angle to the direction of motion through air, this
is created due to differences in air pressure.
c. Thrust - The force that propels the drone in the direction of motion, thrust is
produced by the motors.

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d. Drag - The force that acts in a opposite direction of motion. Drag is caused by
friction and differences in air pressure.

All the four forces together contribute in hovering the drone above the ground.
Multi-rotor drones work on relative nature of force, that means when the rotor pushes
the air downwards, the air will also push the rotor upwards. This is the principle by
which it will go up and down, Lift is directly proportional to speed of rotors rotation.

3.2 Roll, Pitch, and Yaw

Fig 3.2: Roll, Pitch, and Yaw of drones

When it comes to drones there are three terms that define the movement of drones
they are to Roll, Pitch and Yaw (Referring Fig 2.2)
a) Roll: Roll is the rotation of the drone in which the drone tilts either to the left
or right. In order for the drone to “Roll Left”, propellers 1 and 3 must run at
normal speeds along with propellers 2 and 4 run at high speed. Similarly to
“Roll Right”, propellers 2 and 4 must run at normal speeds along with
propellers 1 and 3 run at high speeds.
b) Pitch: Pitch describes the forward and backward motion of the drone. To
“Pitch forward” propellers 1 and 2 must run at normal speeds while
propellers 3 and 4 must run at high speeds. Similarly to “Pitch backwards”,
propellers 1 and 2 must run at high speeds while propellers 3 and 4 at normal
speed.

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c) Yaw: Yaw is the clockwise or counterclockwise spin of the drone. In order

for the drone to “Yaw left” propellers 1 and 4 will move at normal speeds
while propellers 2 and 3 will move at high speeds. Similarly to “Yaw right”
propellers 1 and 4 will move at high speeds and propellers 2 and 3 will move
at normal speeds.

4. PROJCT ESTIMATION
Sl.no Particulars Cost (₹) Quantity

1 Emax CF2822 1200KV 3,200 4

Outrunner Brushless Motor
2 3 blade propellers 300 4

3 10 amps ESC 2,000 4

4 Propeller mounts 300 4

5 Lipo battery 2,000 1

6 Naze 32 Flight board 2,016 1

7 Bluetooth module 2,097 1

8 XT60 connector 400 1

9 Thermal insulation tube 200 As per requirement

10 3D printing 1,260 16

TOTAL COST (₹) : 13,773 INR /-

Table 4.1: Project Estimation

/

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5. SYSTEM OVERVIEW
5.1 Battery
Batteries are the power source for the drones to work, the type of battery used is a
Lithium Polymer battery having 3 cells in arrangement. The battery range is from
1500 mah - 2200 mah. The capacity of the battery is called ‘C’. The specification of
the battery is 2200mah 4S, 25C having 4 cells in series arrangement.

Fig 5.1: Lipo battery 2200mah

5.2 Propellers
3 bladed propellers are used so that there can be a reduction in the size of a drone
when compared to an equivalent large quadcopter with 2 bladed propeller. The
dimensions of the propeller are 6 inch x 4.4 inch pitch, meaning the total area covered
by propeller while rotating is 6 inch and 4.5 inch pitch is the distance covered upon
one rotation of the propeller. We require 2 clockwise and 2 counter clockwise
propellers

Fig 5.2: Tri-blade propeller

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5.3 Motors
There are two types of motors namely brushed and brushless motors. For
multi-rotor drones, since we need to need to generate lift the rotation speed should be
high and there should not be any friction hence brushless motors are used.
Specification for the motor used- Emax 2822 1200KV.
The first two numbers 28 represents the diameter of stator in mm, the next two
numbers 22 represents the length of the magnets that rotate in mm, KV is the number
of turns generated by the motor for each volt, this motor gives 1200 when 1V is
applied.

Fig 5.3: Brushless DC motor

5.4 Flight controller

Flight controllers are the heart and soul of any drone, the flight controller used in
this project is a “NAZE 32” flight board. This flight board consists of sensors like
accelerometer, gyroscope, magnetometer and barometer. The accelerometer and
gyroscope is used to stabilize a drone, the magnetometer is used to stabilize the
rotation of the drone, the barometer is used to stabilize the height of the drone.
Normally Electronic Speed Controllers (ESC) are used to power the flight board as
they can deliver the required voltage on a 3-pin servo cable.

Fig 5.4: NAZE 32 Flight board

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5.5 Electronic Speed Controllers (ESC)

The term ESC stands for “electronic speed control is an electronic circuit used to
change the speed of an electric motor, its route, and also to perform as a dynamic
brake. These are frequently used on radio-controlled models which are electrically
powered, with the change most frequently used for brushless motors providing
an electronically produced 3-phase electric power low voltage source of energy for
the motor.

Fig 5.5: Electronic Speed Controller (ESC)

5.6 Bluetooth module

HC-05 is a Bluetooth module which is designed for wireless communication .It is

used for many applications like wireless headset, game controllers, wireless mouse,
wireless keyboard and many more consumer applications. It has range up to <100m
which depends upon transmitter and receiver, atmosphere, geographic & urban
conditions. It uses serial communication to communicate with devices.

Fig 5.6 HC-05 Bluetooth Module

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5.7 XT60 Connector

The XT60 is a popular connector type that is found in almost all

high-current lithium polymer batteries. These connectors can handle up to 30A and
can be plugged in only one way, preventing the reverse connection.

Fig 5.7: XT60 connector

5.8 3D structure

The structure can either be 3D printed or comprised of plywood processed by

laser cutting, however the preferable choice was to go for 3D printing as it can
provide high geometric accuracy along with high robustness compared to that of a
frame processed by plywood.

Fig 5.8: 3D structures

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6. FABRICATION OF THE DRONE

 Once the parts are 3D printed using 3D materials like Polylactic Acid (PLA),
Elastomeric Polyurethane Resin (EPU) and Thermoplastic Polyurethane (TPU)
the parts have to be assembled to form a drone structure as shown in Fig 4.1:
Drone frame.

Fig 6.1: Drone frame (Isometric view)

 Once the drone structure is completed the electronics have to be fixed on to the
structure, the electronics like battery, motor, ESCs are all fixed to the place using
zip tags and the Bluetooth module along with the flight board are glued to the
structure.
 By referring Fig 5.2: The placement of the propellers and the type of propellers is
also an important part failure to do so will not let the drone to hover off the
ground or will cause the drone to topple over. The Red propellers indicate
counterclockwise props and they should be adjacent to each other and the Green
propellers indicate clockwise props which is adjacent to each other.
 The connection diagrams for the Motors, ESCs, Naze 32 Flight board, and the
Bluetooth module are all shown in Fig 5.3.1 to Fig 5.3.3

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Fig 6.2: Completed drone structure

Fig 6.3.1: Connection of motors and ESCs

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Fig 6.3.2: Connection of motors to NAZE 32 Flight board

Fig 6.3.3: Connection between Naze 32 and Bluetooth module

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Fig 6.4: Top view of finished model

Fig 6.5: Side view of finished model

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7. NAZE 32 BOARD LAYOUT, CONFIGURATION

AND CONTROL

Fig 7.1: NAZE 32 Layout

Fig 7.2: NAZE 32 flight board

 The NAZE 32 is a one of a kind flight controller which has the capability of
supporting the function of 6 motors or even a configuration of 4 motors and 2
servo motors.

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 This flight board seemed to be an effective and budget friendly part for beginners
who are into building drones. The flight board can be configure by using a
software called as “Cleanflight Configurator”, by plugging it into the laptop using
a USB cable and making the required changes as per our knowledge.

Fig 7.3: Cleanflight GUI

 The drone as mentioned earlier is not controlled by a remote but it is controlled

by the movement of the android phone. For instance, tilting the phone forwards
will cause the drone to pitch forward similarly,tilting the phone to the left will
cause the drone to roll left. This can be controlled by using an app called as
“Flone remote” which can be installed ONLY to the phones which have
Gyroscope sensors in them, as it is the motion of the Gyroscope in the phone
which causes the Bluetooth module mounted on the phone to send the command
to the Flight board causing the required change.

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Fig 7.4 FLONE remote App

PRE-FABRICATION WORKS

1. Ensuring all the components are in proper condition

2. Soldering of Brushless motors to ESCs
3. Converging all Motor-ESC connection to XT60 connector by soldering and
providing INSULATION to all points of soldering.
4. Calibration of NZAE 32 by Cleanflight or Betaflight Configurator.
5. Calibration of HC-05 Bluetooth module by Arduino software.

NOTE: Failure in doing either of the above mentioned pre-fabrication works will lead
to an incomplete circuit leaving the drone in a non-working condition and failure to
provide insulation to points of soldering will lead to a short circuit which may cause
the Lipo battery to explode.

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8. DRONE RULES AND REGULATIONS IN INDIA

 According to India's national aviation authority, the Ministry of Civil Aviation,

flying a drone is legal in India, but we recommend being aware of and compliant
with the drone regulations listed below before doing so.

 India's Directorate General of Civil Aviation announced the country's first Civil
Aviation Requirements (CAR) for drones on August 27, 2018 to go into effect
December 1, 2018.

General rules for Flying a drone in India

Based on the research and interpretation of the laws, here are the most important rules
to know for flying a drone in India.

 All drones except those in the Nano category must be registered and issued a

Unique Identification Number (UIN).

 A permit is required for commercial drone operations (except for those in the

Nano category flown below 50 feet and those in the Micro category flown below

200 feet).

 Drone pilots must maintain a direct visual line of sight at all times while flying.

 Drones cannot be flown more than 400 feet vertically.

 Drones cannot be flown in areas specified as "No Fly Zones", which include
areas near airports, international borders, Vijay Chowk in Delhi, State Secretariat

Complex in State Capitals, strategic locations, and military installations.

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India’s No permission, No takeoff policy

 Before every single flight, drone pilots are required to request permission to fly

via a mobile app, which will automatically process the request and grant or reject

it. India is calling their system "No Permission, No Takeoff' (NPNT).

 If a drone pilot tries to fly without receiving permission from the Digital Sky

Platform, he or she will simply not be able to takeoff.

 All drone operators will register their drone and request permission to fly for each

flight through India's Digital Sky Platform. The Digital Sky Platform and further

details will be available on the DGCA website from December 1, 2018.

9. CONCLUSION

 This project gave a strong foundation to get a basic knowledge of how to build

drones from scratch even with no prior experience.

 There is a room for further development of range of control from the phone to the

drone by finding alternate means of control module.

 Further improvements can be made by using alternate source of power like usage

of Photovoltaic cells (PV cells)

 This drone can be used as an alternate to the overpriced drone models provided

this drone has a dual control feature.

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10. REFERENCE LINKS

1. A survey of quadrotor UAV https://ieeexplore.ieee.org/document/6196930

2. Design & implementation of an UAV (Drone) with flight data record

https://ieeexplore.ieee.org/document/7856519
3. Special Issue on Unmanned Aerial Vehicles (UAVs)
https://www.mdpi.com/2076-3417/10/22/8078
4. Unmanned aerial vehicles and remote sensing
https://www.sciencedirect.com/journal/international-
journal-of-transportation-science-and- technology/vol/5/issue/3

5. Unmanned aerial vehicles s https://www.longdom.org/peer-

reviewed-journals/unmanned-aerial-vehicle-26567.html

6. International journal of micro air vehicles

https://journals.sagepub.com/home/mav

7. Unmanned Aerial Vehicle Domain: Areas of Research

https://www.researchgate.net/publication/280577358_Un
manned_Aerial_Vehicle_Domain_Areas_of_Research

8. Unmanned systems https://www.worldscientific.com/worldscinet/us

9. A Review Paper on Unmanned Aerial Vehicle (U.A.V.)

https://www.ijert.org/a-review-paper-on-unmanned-
aerial-vehicle-u-a-v

10. Drones and their possibility of usage

https://www.researchgate.net/publication/305273853_Dro
nes_and_Possibilities_of_Their_Using

11. Flone drone https://flone.cc/

PRITHVI G, DEPARTMENT OF ME, VVCE (2018-22) 23

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