Science & Technology, UK (Commonwealth Union) – The University of Manchester’s engineers have successfully crafted and piloted the world’s largest quadcopter drone. Constructed from a lightweight material resembling cardboard, known as foamboard, this colossal drone spans 6.4 meters (21 feet) from corner to corner, with a weight of 24.5 kilograms – just 0.5 kilograms under the weight limit established by the Civil Aviation Authority.
Distinguished by its groundbreaking design, this drone, aptly named the Giant Foamboard Quadcopter (GFQ), stands in a class of its own. Its four arms comprise a unique series of hollow box structures, allowing for effortless disassembly for transportation purposes. As of the current moment, there is no documentation of any purpose-built uncrewed quadcopter, regardless of weight class, that surpasses the dimensions of the Manchester vehicle.
This endeavor commenced as a curiosity-fueled initiative, aiming to stimulate students’ imaginative prowess in design by adopting an economical, eco-friendly alternative material for lightweight aerospace structures, distinct from the customary carbon fiber. In contrast to carbon fiber, low-density sheet materials exhibit exceptional recyclability potential and, in certain cases, may even be compostable. The researchers aspire to use this demonstration as a catalyst to inspire the up-and-coming generation of designers to embrace sustainability from an entirely fresh vantage point.
Dan Koning, a research engineer at The University of Manchester, spearheaded the vehicle’s design and construction. He expressed that foamboard is an intriguing material for exploration, emphasizing its potential to craft intricate aerospace structures, where each component is meticulously engineered to meet precisely the necessary strength requirements, eliminating the margin for excessive engineering.
“Thanks to this design discipline and after extensive background research, we can say with confidence that we have built the largest quadcopter drone in the world.”
Although this drone was initially conceived as a proof-of-concept endeavor, subsequent iterations of this aircraft model could be tailored for transporting substantial payloads across short distances or for acting as a “mothership” in aerial docking experiments.
The quadcopter was meticulously crafted from 5mm-thick foamboard sheets, which feature a foam core encased in a paper skin. These sheets were precision-cut with laser technology and meticulously assembled into a three-dimensional structure by hand, employing only hot melt glue.
Josh Bixler, a globally acclaimed YouTuber and trailblazer in the realm of remote-controlled aviation, assumes the role of President at Flite Test, the company responsible for producing the foamboard utilized in the GFQ.
Reflecting on this project, Josh indicated that frequently, advanced aircraft incorporate expensive materials, but they firmly believe it doesn’t have to be that way. Witnessing engineers stretch the boundaries in such an accessible, yet spectacular manner was a source of inspiration and showcased their innovative, unconventional thinking.
The GFQ is propelled by four electric motors, which draw power from a 50-volt battery pack. It is additionally equipped with an onboard flight control system, allowing it to operate autonomously.
The maiden flight took place on July 5, this year, within the primary hangar at the Snowdonia Aerospace Centre, coinciding with the CASCADE Collaboration Workshop Week. During this event, teams from various universities across the UK convened to showcase their latest research technology and engage in brainstorming sessions aimed at fostering innovation.
Kieran Wood, who is a Lecturer of Aerospace Systems at The University of Manchester, who was the pilot of the vehicle, says “The first moments of flight are the make-or-break point for these types of multi-copter drones. There are many hundreds of things that you must get right. If everything has been designed and built well, we expect success, but any problems will become very apparent in a rapid unscheduled disassembly on the first take-off.”
This project is an extension of the earlier achievement from last year, where a similarly expansive fixed-wing foamboard aircraft demonstrated remarkable success. Subsequent to this accomplishment, a dedicated student society was established at the University, with a singular focus on advancing the development of sizeable, lightweight foamboard Unmanned Aerial Vehicles (UAVs).
