Drone Propeller Thrust Stand

Testing Robotics Data Analysis 3D Printing
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Overview

Building reliable drone propulsion starts with rigorous testing. I developed a thrust stand for a drone delivery startup to validate yaw thruster performance. The thrusters operate inside ducts, generating bidirectional thrust. The system automates endurance, thermal, and vibration testing—delivering high-fidelity data to improve performance and durability.

Technical Details

  • Systems: 6DOF load cell, rotary encoder, accelerometers, thermocouple.
  • Propulsion: BLDC motor with injection-molded propellers inside ducts.
  • Testing Scope: Torque profiling, endurance, thermal, vibration analysis.
  • Data Collection: Python-based test app for automated logging.
  • Manufacturing: CNC-machined aluminum hub, SLS 3D-printed aero surfaces.
  • Simulation & Optimization: CFD, FEA, failure criteria definition.

Development Process

  1. Concept & Design: Modeled complex aerodynamic surfaces in Siemens NX, ensuring realistic flow behavior over the ducts.
  2. Prototype & Fabrication: Built the stand from machined aluminum and steel. Used 3D printing to validate airflows before finalizing injection-molded propellers.
  3. Testing & Data Analysis: Integrated a motor controller, load cell, and encoders to collect torque and thrust data. Wind tunnel tests refined performance.
  4. Optimization & Refinement: Defined failure criteria and optimized thruster efficiency through CFD, FEA, and vibration testing.

Results

  • Reliable Testing Platform - Enabled automated, repeatable tests for thrust and endurance validation.
  • Enhanced Performance Insights - Data-driven improvements in thrust efficiency, duct geometry, and motor performance.
  • Manufacturing-Ready Design - Designed for DFM/DFA, ensuring smooth transition from prototype to production.