Quadcopter Drone Design & Prototype
CATIA V5 • SOLIDWORKS • (FEA)
Overview
Designed a complete quadcopter platform from scratch in CATIA V5, including the frame structure, propulsion integration, and electronics mounting layout. Static structural analysis was performed during the design stage to evaluate arm stiffness and stress distribution under thrust loading before manufacturing the prototype.
Technical Snapshot
Takeoff Weight
~1.5 kg
Motor-to-Motor Span
450 mm
Motors
1200 kV brushless
Propellers
10×5
Frame Material
3D-printed PLA
Maximum Arm Deflection (FEA)
~1.5 mm
Scope of Work
• Designed the complete quadcopter frame architecture in CATIA V5
• Integrated motor mounts, central electronics plate, and landing structure
• Selected propulsion system based on thrust-to-weight requirements
• Performed static structural analysis of the frame under motor thrust loads
• Optimized arm geometry by removing material in low-stress regions
• Evaluated stress distribution and deformation using FEA
• Prepared geometry for additive manufacturing
• 3D printed the frame and assembled the drone
Outcome
The frame was manufactured using 3D printing, assembled into a quadcopter platform, and successfully flown. The physical prototype confirmed that the lightweight optimized geometry provided sufficient stiffness and structural integrity during operation.