Practical UAS Development: From CAD to Autonomous Flight
Practical UAS Development: From CAD to Autonomous Flight
⭐ FLAGSHIP PROGRAM
From zero to autonomous flight in 10 days. Design, 3D print, assemble, program, and fly your own aircraft.
Course Overview
This intensive 10-day program takes students through the complete UAS development lifecycle—from CAD design and 3D printing through ArduPilot configuration and autonomous mission execution. You’ll build a fully functional Group 2 fixed-wing aircraft and leave with the knowledge to replicate the process.
Platform: 1600mm twin-motor fixed-wing (“Moose”)
Duration: 10 days (80 contact hours)
Schedule: 8 hours/day + optional evening lab access
What You’ll Build
Students design, fabricate, and fly a purpose-built autonomous recon platform featuring:
- 1600mm wingspan, 1000mm length twin-motor configuration
- V-tail control surfaces for simplified mechanics
- Fully 3D-printable airframe (LW-PLA lightweight filament)
- Carbon fiber spar reinforcement for structural integrity
- Modular payload bay for mission-specific sensors and equipment
- ArduPilot Plane flight controller with autonomous capability
- 40km+ telemetry range (RFD900x radio system)
You keep the aircraft (retail value: $800-$1,200)
Week 1: Design, Fabrication & Assembly (Days 1-5)
Day 1: Design Intent & CAD Fundamentals
- UAS design principles and aerodynamic basics
- Introduction to Fusion 360 / OnShape (student choice)
- Platform walkthrough and design rationale
- Modification planning: Students identify one custom change
Day 2-3: Additive Manufacturing
- FDM 3D printing with LW-PLA (lightweight PLA)
- Print orientation, supports, and quality optimization
- Slicing software (Cura / PrusaSlicer)
- Students print their airframe components (overnight prints supervised)
Day 4: Structural Assembly & Reinforcement
- Carbon fiber spar installation and bonding techniques
- Hinge installation for control surfaces
- Fuselage assembly and integration
- Landing gear mounting
Day 5: Power Systems & Propulsion
- Battery selection and power budget calculation
- Motor and ESC pairing for twin-motor configuration
- Power distribution board (PDB) wiring
- Servo installation for control surfaces
- Introduction to domestically-sourced avionics options
Week 2: Programming, Testing & Flight Operations (Days 6-10)
Day 6-7: Flight Electronics & ArduPilot Configuration
- Flight controller installation (Pixhawk / Cube Orange)
- Sensor calibration (accelerometer, compass, airspeed)
- ArduPilot parameter configuration for twin-motor platform
- Radio transmitter setup and failsafe programming
- Telemetry system integration (RFD900x)
Day 8: Ground Testing & Pre-Flight
- Control surface deflection and throw verification
- Center of gravity (CG) calculation and balancing
- Motor thrust testing and ESC calibration
- Mission Planner / QGroundControl software training
- Pre-flight checklist development
Day 9: Manual Flight Operations
- Hand-launch techniques and flight safety
- Manual flight training (instructor-led)
- Trim adjustments and flight envelope exploration
- Landing approach and recovery procedures
- Flight log analysis and performance optimization
Day 10: Autonomous Operations & Final Assessment
- Waypoint mission planning in Mission Planner
- Autonomous takeoff and landing configuration
- Multi-waypoint mission execution
- Return-to-launch (RTL) and failsafe testing
- Final Capability Assessment (1-5 rating scale)
Assessment & Certification
Students are evaluated using a 1-5 capability rating scale across four phases:
Phase 1: Design & Fabrication (Can you build the aircraft?)
Phase 2: Systems Integration (Can you wire and configure it?)
Phase 3: Manual Flight (Can you fly it safely?)
Phase 4: Autonomous Operations (Can you program and execute missions?)
Passing Standard: 3/5 (Competent) or higher in all phases
Rating Scale:
- 5 - Expert: Can teach others, troubleshoot novel issues
- 4 - Proficient: Independent operation, handles most scenarios
- 3 - Competent: PASSING - Performs tasks with occasional guidance
- 2 - Developing: Requires supervision, building skills
- 1 - Novice: Learning fundamentals, heavy support needed
Certificate Awarded: Practical UAS Development Completion Certificate
Pricing & Registration
| Customer Type | Price per Student | Notes |
|---|---|---|
| Department of War / Government | $18,500 | Active duty, federal agencies |
| Commercial | $16,500 | Private sector, contractors |
| Academic | $14,500 | Universities, research institutions |
| Early Adopter | $12,500 | First 3 cohorts (2025-2026) |
What’s Included:
- Complete autonomous recon platform (yours to keep)
- All materials and components
- Minimum 80 hours of instruction (full days)
- ArduPilot configuration files
- Post-course support (90 days)
- Digital training materials
Not Included: Travel, lodging, meals
Prerequisites
No prior experience required. This course is designed for motivated learners with:
- Basic computer literacy (file management, software installation)
- Willingness to learn CAD software (we teach from scratch)
- Physical ability to assemble components and perform field operations
- Commitment to full 10-day attendance (no partial completion)
Recommended (Not Required):
- FAA Part 107 Remote Pilot Certificate
- Basic electronics or RC aircraft experience
Class Size & Schedule
Maximum Students: 12 per cohort
Minimum Students: 4 per cohort
Instructor Ratio: 1:6 maximum (2 instructors per full cohort)
2025-2026 Schedule:
- Cohort 1: March 10-21, 2025
- Cohort 2: June 9-20, 2025
- Cohort 3: September 8-19, 2025
- Cohort 4: December 8-19, 2025
Custom Cohorts Available: Contact us for dedicated group training (minimum 6 students)
Location & Facilities
Training Location: Fayetteville, North Carolina
Proximity: 10 minutes from Fort Liberty (formerly Fort Bragg)
Facilities Include:
- Climate-controlled classroom and lab space
- FDM 3D printers (Prusa, Creality, Bambu Lab)
- Electronics workbenches with soldering equipment
- Flight operations area with controlled airspace access
- Secure aircraft storage
What Students Say
“I went from knowing nothing about 3D printing or ArduPilot to flying my own autonomous aircraft in 10 days. The hands-on approach and capability-based assessment kept me accountable.”
— J. Martinez, Department of War Contractor
“Best training investment our research lab has made. Our team can now design and build custom platforms for our sensor payloads instead of buying off-the-shelf.”
— Dr. Sarah Chen, University Research Scientist
Post-Course Support
Included for 90 Days:
- Email support for technical questions
- Access to private online community (Discord)
- STL file library for spare parts
- ArduPilot parameter file updates
Optional Add-Ons:
- Extended support (1 year): $1,500
- On-site assistance for first operational deployment: $3,500/day
- Custom platform design consultation: $200/hour
Registration & Contact
Ready to build your first autonomous aircraft?
Email: info@forgeandflightacademy.com
Phone: (910) 555-0147
Website: www.forgeandflightacademy.com/register
Payment Terms:
- 50% deposit to secure seat
- 50% balance due 30 days before course start
- Cancellation policy: Full refund if cancelled 60+ days prior
Frequently Asked Questions
Q: Can I modify the design during the course?
A: Yes! Day 1 includes modification planning. The platform specifications are 1600mm wingspan and minimum 1000mm length. Common changes include payload bay customization, landing gear selection, and paint schemes. Students build, design payloads, test, and keep their completed aircraft.
Q: What if I can’t attend all 10 days?
A: Full attendance is required—all 10 full days with minimum 80 contact hours. The curriculum builds sequentially—missing days creates knowledge gaps that prevent capability demonstration.
Q: Do I need to bring my own tools?
A: No. All tools, equipment, and materials are provided. Bring a laptop (Windows/Mac/Linux) for CAD and mission planning software.
Q: Can I fly the aircraft after the course?
A: Yes, you own it! You’ll need an FAA Part 107 certificate for commercial use. We provide comprehensive Part 107 prep materials and will fund your exam cost (up to 2 attempts) at a local FAA-authorized test center in Fayetteville. If you don’t pass the first time, we provide remedial training before your second attempt. You’re responsible for complying with local airspace regulations.
Q: What’s the failure rate?
A: ~10% of students don’t achieve “Competent” rating in all phases on first attempt. Common issue: insufficient practice on Day 8-9. Students can return for refresher training at reduced cost.
Q: Is this course ITAR-controlled?
A: No. Training covers openly-available ArduPilot software and commercial components. U.S. persons only (no export-controlled content).
Build It. Program It. Fly It.