Development of a 100 kg-class Heavy Cargo Drone with Single-Propeller Failure Tolerance
Duration: January 2023 – December 2024
Lead Organization: VSPACE
Role: Project Lead for Full Aircraft Development
Project Overview
This project focuses on the development of a heavy-lift X8 multicopter drone with a maximum takeoff weight (MTOW) of 225 kg and a payload capacity of 100 kg. Unlike conventional multicopters, this platform is designed to tolerate single-propeller failure while maintaining controlled flight, enabling safe deployment in high-risk delivery and logistics environments.
The project includes mechanical design, frame reinforcement, structural validation, flight controller configuration for fault handling, and actual demonstration of stable flight with simulated failures.
My Contributions
- Designed and assembled the entire drone frame for high-load conditions
- Integrated high-voltage battery pack with custom STM32-based BMS and CAN communication
- Performed structural analysis (FEA) to verify integrity under propeller failure torque
- Configured fault-tolerant X8 motor layout with custom flight controller tuning
- Executed tethered and untethered flight tests with single-motor failure scenarios
Outcomes
- Successfully demonstrated real flight with single-propeller fault tolerance
- Validated structural and power system resilience for 100 kg-class logistics missions
- Confirmed effectiveness of BMS, ESC synchronization, and vibration resistance
Gallery
YouTube Demo
This project was documented through a 4-part video series showing the full development and fault-tolerant flight validation process.
- ▶ Part 1: Frame Design and Structural Assembly
- ▶ Part 2: Welding and Power System Integration
- ▶ Part 3: Final Assembly and Power-On Test
- ▶ Part 4: Tethered and Free Flight Fault-Tolerance Demo