Project Description
### Overview:
I am seeking an experienced aeronautical engineer or aircraft designer to develop a clean-sheet, 3D-printable fixed-wing UAV airframe.
This aircraft is built around a simplicity-first, stability-driven design philosophy. It uses a twin-motor tractor configuration and eliminates all movable flight control surfaces (no ailerons, rudder, elevator, or servos).
Control is achieved entirely through thrust modulation:
* Total thrust for climb and descent
* Differential thrust and accelerated lift effects for turning
The aircraft is intentionally low in maneuverability and must be inherently stable, with stability driven by strong dihedral and a low center of gravity. It should naturally return to wings-level flight without active correction.
### Specifications:
Configuration:
* Fixed-wing UAV
* Twin tractor motors mounted on wing leading edge
* Counter-rotating propellers (CW left, CCW right)
* Motors angled slightly upward and outward to assist turning and mitigate asymmetrical thrust-induced yaw
* No movable flight control surfaces
Flight Behavior:
* Climb / descend via total thrust
* Turning via differential thrust and induced lift asymmetry
* Predictable, self-correcting flight
Size & Performance Targets:
* Wingspan: ~1.7–1.9 m
* Payload: ~1 kg
* Estimated MTOW: ~2.5–3 kg
Manufacturing & Assembly:
* Designed for Bambu Lab printer (256 × 256 mm bed)
* Minimize number of sections while staying within print volume constraints
* Seamless assembly using alignment pins and interlocking features
* Minimal or no glue (press-fit preferred)
* Wing must be removable using a single tool and support repeatable assembly/disassembly
Structural & Internal Layout:
* Payload bay located near CG
* Internal wiring channels for ESC cables and lighting
* Integrated motor mounts in wing leading edge
* Structural design optimized for weight and strength
* Carbon fiber spar reinforcement expected (designer to specify)
* Material selection per section (PLA / PETG / ABS as appropriate)
Engineering Scope:
* Aerodynamic design and validation (XFLR5 or equivalent)
* Define airfoil, wing planform, and dihedral
* Generate lift/drag polars, stall estimate, CG range, and static margin
* Structural optimization for load paths and print efficiency
* Print optimization (orientation, supports, layer direction)
### Deliverables:
* Native CAD files (Fusion 360 preferred; SolidWorks/STEP acceptable)
* Print-ready STL files (organized by section)
* CG location and recommended range
* Recommended dihedral angle
* Documentation:
* Aerodynamic analysis summary (polars, stall, stability)
* Structural and reinforcement recommendations
* Material selection per section
* Print settings and orientation per part
* Assembly instructions
### Ideal Candidate & How to Apply:
This project requires a strong aeronautical engineering background — not just CAD proficiency.
You should have:
* UAV / aircraft design experience
* Deep understanding of static stability (CG, neutral point, static margin)
* Experience with low Reynolds number aerodynamics
* Proficiency in:
* XFLR5 or similar tools
* CFD (Ansys Fluent, CFX, or equivalent)
* FDM design-for-manufacturing
* Structural / topology optimization
To apply:
* Provide relevant project examples (UAV, RC aircraft, or aerodynamic designs)
* Include a brief list of key technical challenges you anticipate in this design