World’s largest quadcopter drone takes flight

 Engineers at the University of Manchester set out to construct and operate the largest quadcopter drone ever, and in order to comply with aviation regulations, they had to choose some unusual materials.

The Manchester team developed a design that weighed 24.5 kg (54 lb) to sneak under the limit, which is the lowest takeoff weight that UAVs can fly under without special permission from the UK Civil Aviation Authority (25 kg or 55 lb).

The big quad project began as “a curiosity-driven venture to inspire students’ creativity in design by utilizing a suitable alternative low-cost material for lightweight aerospace structures that is more environmentally friendly than the usual carbon fiber.”

The students decided on a hollow box-frame design made of 5-mm (0.2-in) thick foamboard, which is composed of a foam core with paper skin, after deciding against using strong, lightweight carbon. The frame was constructed by hot-gluing together laser-cut foamboard sheets.

“Working with foamboard is an interesting material,” stated Dan Koning, the design and build team leader and research engineer. When used properly, they allow us to build intricate aerospace structures in which no part is over-engineered and is only made to be as strong as it has to be. We have constructed the largest quadcopter drone in the world, and we can claim it with confidence because of this design discipline and thorough background study.

The drone measured an amazing 6.4 meters (21 feet) from corner to corner. A news release from the University of Manchester stated, “As of the time of writing, there is no record of a purpose-built uncrewed quadcopter (four rotors) of any weight class which is larger than the Manchester vehicle.”

Larger electric VTOL aircraft prototypes exist, of course, but they require more than four propellers. Anyone who feels like putting in the time can likely find a rather easy route to a world record thanks to the team’s self-imposed no-carbon restriction! Watch the video below to see this large bird take off.