Hardware

UAV OPTIMIZATION & INTEGRATION

POWER EFFICIENCY & SUSTAINABILITY

STREAMLINED UAV ASSEMBLY

MISSION

The Hardware Team designs, manufactures, and validates the physical systems that make autonomous flight possible, translating concepts and plans into reliable, flight-ready platforms. Hardware works closely with the Airdrop, Machine Learning, and Autopilot subteams to ensure the aircraft can safely carry sensors, compute systems, and payloads while maintaining stability, efficiency, and durability in real-world operating environments. Two core focus areas drive development: Structures and Propulsion.

STRUCTURES

The Structures Team designs and fabricates the physical multirotor airframe and structural interfaces that support avionics and payload systems, with a focus on structural integrity, vibration management, and subsystem optimization. Using SolidWorks for CAD and in-house fabrication tools, additive and subtractive manufacturing methods are employed - including carbon fiber composites, reinforced filaments, CNC machining - to maximize mechanical strength while reducing weight and flex. Designs are validated through load analysis and extensive testing in the Rutgers Aerospace Lab for PID tuning and fast iteration.

PROPULSION

The Propulsion Team designs and integrates the thrust and power systems that define vehicle performance, focusing on sensors, wiring, power distribution, and autopilot integration. Using simulation tools alongside empirical testing, the team evaluates motor and propeller combinations, ESC integration, and battery configurations to ensure stable, efficient, and scalable flight across mission profiles. The team also ensures reliable communication throughout the electrical system while mitigating electrical noise between radios, flight controllers, ESCs, and motors. Thrust-to-weight ratio, thermal margins, efficiency curves, and endurance targets are evaluated throughout the design and validation process.

HARDWARE LEAD


William Carney

Mechanical Engineering | Class of '27