Project Logs

We are now researching for new sensors that need to be added to aid pitch axis PID like altitude and optical sensors. We are still fine-tuning our other axes so that we get perfect our PID till we get the new sensors. We also need to try balancing the weight and dampen or fix the vibrations in the aluminium wing frame caused because of the motors.
Baby flights

With our new batteries in place and our PID looking all good, we tested our vtol and for the first time we saw our vtol hoping not once twice. With great results we are not looking for a full flight testing but with pitch axis yet to be tuned, we also need to check for the full power thrust measurements and the entire system checks.
Check out our vtol hop video

After so much waiting and patience finally the batteries were in stock online, and we got it delivered. We now have new batteries and new 1045 propellers. We are now quite encouraged and determined to get our work done with so many worries out of the way Rajas, tested the new batteries and the propellors.

Rajas and Sahil start finding for battery alternatives, because of the thrust issues which were caused from the last version. We have been waiting for them to come in stock online and also find in local stores, with 3S LiPo batteries as the main target. With almost 1 month after finding the issue and searching for batteries, we play the waiting game.

Rajas worked overnight to complete the new frame for the vtol. Using medium-density fibreboard for the mainframe which will be holding the brain of the vtol and the battery as 2 bases hold them up, with an aliminium rod wingspan passing across and two small landing legs. We have updated a lot of our code by referencing open source codes with 2 axes of roll and yaw tuned properly for our current version.

We did a lot of progress this year with the new drone parts, and new code for all the motor controls and radio communication. We will be switching to a new design, worked out by Rajas for the entire vtol frame from the current primitive structure we had. This new structure will be more robust and light-weight. With hopes to get the project complete in the new year 2026, we will be working with great strength starting from the first month itself.

With no replies from anyoen, we keeping going forward with whatever we have in our hands. Currently we find some thrust issues because of some fault with the motor or the battery. We are trying to find it. We will be trying to add another motor and test it out as per Rajas

While we wait our mails to be replied, we keep upgrading our work. We start tuning our yaw axis PID. Currently our vtol performing rotations about its own yaw axis.

We start sending mails to various Indian and other international companies who have offline stores in or near Mumbai, to acquire our own 3d printer or atleast get some discount. Our locally printed 3d printed parts keep breaking and failing while testing, we have tried getting our design better, but still for future iterative works we will be needing some help.

We create a document showing what all work we have done so far, for geting some sponsorship or aid for our 3d printing work. We will be trying to contact companies to get some support for 3d printers for our work as student hobbyist project.

Update some of the roll axis code using the dRehmFlight flight controller open source code.

Recent VTOL drone tests show 12-second indoor hovers with improved stability, thanks to a new cascaded PID controller. Upgraded brushless motors and propellers, combined with web-based PID tuning, have resolved earlier flight issues. The control system now separates angle and rate management, reducing oscillations.
Check out the test video

Faced instability in VTOL drone during lift-off due to propeller imbalance. Upgrading props, motors, and frame to improve stability.

Acquired electrical connectors, enabling final wiring for the tilt-rotor transition mechanism. Prototype features a 3D-printed servo mount integrated with a 2200KV brushless motor, assembled with affordable hardware and basic soldering tools. Code and transition mechanism design finalized; optimistic about progress, though potential new issues are anticipated.

Rajas, Swar, Sahil held a vc for buying new motors. Surpisingly no one noticed that both the bldc motors were counter-clockwise. Had to buy new clockwise motors!

With new enthusiasm we work again. This time we have almost everything ready. Rajas is now working on reducing the weight of the model. By reconsidering the materials, and the required parts.

The 3d printed structure is delivered and assembled. The new holder is sleek, strong, and durable! The mainframe is ready for testing on the next Sunday.
Check out the main frame of our VTOL design

We have been trying to find a more suitable and strong design for the motor holder as our old one broke.Rajas has been modelling some designs and has identified the stress points. We will be using 3d printing for the new design that we model.
VTOL Design Update: Von Mises Stress Analysis & 3D Printing Pivot (June 2025)

We have been coding a lot of changes in the flight control, including new PID control code and security measures for in-flight risks. With new code to be tested, we decided to use the date from the receiver and visualize it using ground control station (GCS) system in simpler terms 3d model environment, before testing it in real life.

Swar proposed a new website design, with an interactive model of Ironflake as the main attraction. With some great visuals for photo gallery and log updates. The new website will be more minimal, and COOL. We will surely update when the website goes live.

Check out some sample images of new website design!!

After testing the flight on 26th, Rajas started testing the PID with roll stabilization as the first priority. Mounted on the testing stand, with 10 percent throttle, the ironflake started oscillating, and the PID control system, wasn't working out. With gains and factors tested out, we decided to work on the code again, so that we can stop oscilations.

Video of Flight Testing

We started working on the PID control system and DMP in the MPU for controlling and stablizing our flight. Also we tweaked our joysticks that suited our use-case. Along with that we tried tested the Proportional factoring code in real life, by throttling the vtol at medium levels.

After facing some difficulties in the setup, we will have to do work on PID as it is still in ground 0 level.

After a long break, we have started making the flight testing setup. A new frame for holding the body as we throttle it up. With new BMS and ESCs we start our journey in flight testing.

The new BMS was added in the system and now the power is on point. With these we have no ESC resets as it is calibrated perfectly.

As we faced issues with ESP32 communication with the Arduino, now Arduino Nano will be the receiver and the ESP32 will do all the calculations. With the new code the masters and slaves of the receiver are swapped. Now along with that the buck converter got blown due its lack of reverse polarity protection.

A new BLDC ESC was bought along with the following parts for the thermals:

1. Universal Heat Sink x 2
2. Aluminium Heatsink with Blue Thermal Tape x 1
3. LM2596S with SMD LED DC-DC Step-Down Power Supply x 1
4. Pro Range Cooling Fan x 1

We were having some issues with the BLDC motors spinning. Right now the issue is solved hoping it won't happen again. The thrust was calculated again at 70% power which came out to be 1.2 kgs for each motor.

After buying the batteries Rajas created a battery pack. Along with it he added the oled screen to the remote which will display the battery percentages and other data as required.

After having a hard time integrating the antenna module NRF24 with the new ESP32 on the receiver. Swar successfully established communication and data transfer. Now we need to make a new battery pack.

The following parts were ordered:

1. Orange A Grade ISR 18650 3.7V 1300mAh 15C Li-ion Battery x 6
2. ESP32-CAM-MB MICRO USB Download Module x 1
3. 18650 2x1 Battery Cell Spacer/Holder x 4
4. Battery Connection Welding Strip with 99.96% Pure Nickel 5Pcs

During several motor run tests the holder broke while going into the hovering phase, causing a new design change to cover the stress on certain points on the 3d printed parts. With the new design printed a sturdy and efficient motor holder were swapped in place of the old ones. Along with that ESP32, was soldered on the receiver module. The new ESP32 has more storage and energy capacity helping for more commands to run.

The entire strucutal frame was assembled with the motors and servo placed with the fuselage along with the ESCs and comms holders.

After breaking the 3d printed holder of the motor, Rajas has firmly secured the motor and the entire structure with the 3d printed holder.

Today transition mechanism and vertical to horizontal swivel mechanism was tested.

40(A) BMS for just was bought.

The following parts were purchased:

1. Arduino Nano
2. NRF24 with antenna
3. 2 Switches
4. Display
5. Resistors

The parts arrived and were mounted to the frame. The hop test will be conducted in the 2nd week of December.

The mount for the motors and to make the transition design, a 3d structure is ordered costing 320 INR for the whole order.

And he delivers. Rajas does what he always does. Best soldering work, with clean and simple design. Check this out: Photos of the reciever module

The ordered parts are delivered and now the work of building the receiver pcb starts. The greatest solderer of all time Rajas will now handle the task of putting all the parts together.

Rajas Calibrated the gyroscopic system, which will help the vtol to be stable in mid air, and not lose its balance due to strong winds and other external factors. Now we are waiting for other parts to be delivered like: header pins, bigger servos and voltage regulator.

Rajas made the battery and bms was integrated in it. The beasty power supply is ready to put on the frame.

Rajas conducted a test by suspending the whole frame to a thread, and tested the motors. The model looked like a dragonfly. The frame looked quite disbalanced due to absence of gyros.

Rajas changed the design by using a modified male-female joint mechanism. It was sturdy, and good to go forward.

The team met on sundays and made upgrades to the design, like trying new design for holding servos and motors, improving radio module and changing the whole body design. The team then tried modelling various transition mechanisms.

To start making the VTOL frame, PVC pipes were bought.

3S 25 Ampere Battery Management System was bought.

Rajas calculated the net thrust to be 600gms of one pair of thrusters. So we have around 600gms to play with!

The following parts were bought today:

1. Lithium Ion cell × 3
2. Load cell
3. Load cell module
4. XP Connector (ESP)

All the parts are now recieved. Rajas and Swar tested all the parts. The propellors and the servos were all running fine. For the next steps a vc will be held tomorrow.

A vc was conducted today, the following parts were purchased:

1. SimonK 30A BLDC ESC Electronic Speed Controller with Connectors × 2
2. A2212 6T 2200KV Brushless Motor for Drone (Soldered Connector) × 2
3. SG90 Micro Servo Motor × 5
4. Quadcopter propellers 10 x 4.5 (1 Pair) × 2
5. Male to Female Jumper Wires (20cm) 40pcs × 1

A vc was conducted today, the topics discussed are:

• The problem with NRF24L01 module with antenaa: The modules of transmtitter and receiver were replaced, as the NRF24l01 module with antenna wasn't transmitting data.Rajas then swapped the module with SMD module with antenaa which was placed in the reciever.
• The purchase of BLDC motor: The team needs to contribute for the money which will be needed to buy the motors. In total 2 motors need to be purchased, and everyone will try and find motors with the required specs and budget.
• Design of the VTOL: Norwin and Sahil will be looking at the designing of the vtol as well as the marterial. They will collaborate with one another for the same.

Rajas with the help of Norwin's and Swar's code has succesfully tested the working of servo. The transmitter is giving the instructions properly while the receiver is capturing the movements of the server and showing proper output. The servo was wirelessly controlled using NRF24L01! Watch this video made by Rajas Naik

Rajas and Swar have achieved complete radio communication. They have successfully assembled transmitter module on PCB board!

Rajas has achieved partial radio communication.

The following parts were purchased by:

1. Data Cable (1)
2. NRF24L01 3.3v Adapter Module (2)
3. 100μF Capacitor (2)
4. 10μF Capacitor (2)
5. GPIO Header pin (8)

Swar has completed the coding of transmitter. He has also completed testing of all the parts he had with him and performed tests by completing the circuit for transmitter.

Today 7 June Swar, Rajas, Sahil went for shopping Parts bought today:

1. Arduino Nano (2)
2. NRF24 with antenna (1)
3. NRF24 without antenna (1)
4. Joystick module (2)
5. Port B to USB cable (1)

Sahil — Today at 10:58 PM: This is the bill of the above mentioned items which mentions the amount 810. The item 5. Port B to USB cable (1) is not mentioned as it was purchased after obtaining Microchip and cuz we didn't check while buying The cost of the item 5. Port B to USB cable (1) is 30/- INR.

Sahil — Today at 11:06 PM: As of now Swar will be testing a few parts from the above mentioned list which include:

• Arduino Nano (1)
• Joystick Module (1)
• Port B to USB cable (1)

Rajas has the remaining parts. He has posted a photo suggesting that the parts need to be cleaned up using "rubbing alcohol". I am "assuming" that he will be doing it by himself as I haven't received any update on it by him at the moment of writing this message.

From today's vc: NR is going to do movement control. A irl meeting is going to be conducted at Eren Jeager's house in the forthcoming days Swar has completed the coding of reciever, and Rajas will be working on the design when he will return home. Sahil will be there to help you all. Till now No one has asked to But I am Here.