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UAV programme

A family of electric drones and a trailer-mounted electromagnetic launcher, for a funded MOD project.

Project
MOD-funded programme
Role
Design team member; lead designer on the canard concept
Outcome
Five carbon-fibre drones and two launch trailers delivered
A render of a black fixed-wing drone with twin tail fins.

Challenge

Develop a family of electric drones, and a trailer-mounted launcher capable of getting them to high speed over a very short distance.

What I did

I was part of the team delivering three drone designs and a trailer launcher that uses an electromagnetic rail system to launch them. I contributed to drone design, prototyping and component development across the programme.

A drone prototype mounted on a roof rack on a blue pickup at an airfield.
A render of the drone flying over farmland.
A ducted fan inside a woven carbon fibre cowling.
Side-view CAD of a drone fuselage showing its internal layout.
CAD of a slender drone with long straight wings.
CAD of an olive green drone sitting on its launch rail.

The canard concept

The second drone concept needed to test a canard configuration quickly and at low cost. I led its design and prototyped it using folded sheet metal and 3D-printed parts to prove out the layout.

The working prototype informed the development of the final carbon-fibre drone.

Exploded CAD view of the canard drone, showing its sheet metal body and internal components.

The launch trailer

The launcher had to accelerate the drones to high speed over a short distance, and its magnets and electronics depended on every part being precisely aligned along the full length of the system.

I was part of the team that designed and built it. It combines CNC-machined, sheet metal and 3D-printed parts, all held to tight tolerances over a 6-metre length so the electromagnetic system worked as intended.

CAD section of the launch rail, showing the magnet carriage and electronics.
The olive green launch trailer with its rail raised, inside a tent.
Ethan standing on the launch trailer during the build.
Olive green sheet metal battery enclosures for the trailer, stacked in the workshop.

Outcome

A successfully funded MOD project. Two fully built launch trailers were delivered, and five carbon-fibre drones were used for demonstration.