Have you ever considered transcending the imagination domain into innovation and creativity?
I will briefly introduce myself and the UIAS (Unmanned Intelligent Aerial Systems) Society to kick-start the conversation. My name is Theresa Boateng, and I’m currently pursuing an MSc in Environmental Engineering at Cranfield University and serving as the Public Relations Officer for the society.
UIAS society; is a group of students delving into the design, building and testing of unmanned aerial vehicles in a series of missions. I am deeply excited to share the collective experience of the team in working on our latest project—the IMechE UAS (Unmanned Aerial Systems) Challenge.
The significance of this challenge is detailed in how it brings together technological and engineering innovation, creativity, and teamwork. These key elements align with our passion as a society to drive impactful change in the field of engineering. The goal is clear: design, build, and operate a UAV capable of completing a set of predefined tasks while adhering to rigorous performance and safety standards. Success will be measured by our UAV's flight performance, mission accuracy, and the knowledge and skills we gain throughout the process.
Unequivocally, the skills we will gain through this journey in the form of teamwork spirit, critical thinking, resilience, leadership, tolerance, adaptability, time management and some other soft skills will be a lifelong invaluable asset.
Project Overview
The IMechE UAS Challenge, launched in 2014, is an annual international competition in which university teams design and develop a fully autonomous UAV capable of performing complex missions, such as package delivery or environmental monitoring. This project aims to promote the practical application of engineering skills, encourage innovative solutions, and enhance collaboration among engineers.
Each October, student teams complete a design and development process for an Unmanned Aerial System (UAS) with a maximum take-off weight of 10kg to accomplish defined mission goals. The project concludes with a final fly-off competition which is held in June or July of the ensuing year.
Our project began with a detailed analysis of the competition requirements. This involved understanding the payload specifications, flight endurance, autonomous navigation criteria, sustainability of aircraft and environmental constraints. Knowing the primary role UAS configuration plays in achieving the mission target, a configuration comparison study was conducted amongst the three dominant types of aircraft; fixed wing, multirotor and the hybrid VTOL. After a detailed analysis of mission requirements, the team selected a hybrid VTOL (Vertical Take-off and Landing) configuration.
Development Process – What does it entail?
Design and Prototyping
Our aircraft design journey has now reached a significant milestone with the finalisation of the design. The team has diligently worked through detailed simulations using CAD software to refine aerodynamic properties and pinpoint the optimal configuration for stable flight. Material selection was crucial in this phase; composite materials such as fibreglass and sandwich panels were chosen for their excellent strength-to-weight benefits, while balsa wood and carbon fibre rods were selected to reinforce the wing ribs, spars, and tail booms.
The design ensures that the aircraft can perform precise take-offs and landings in confined areas, operate at speeds below 40 KTAS, and maintain altitudes under 200 feet AGL. The payload is engineered to be detachable from the main structure, supporting both modularity and ease of operation, while structural integrity has been carefully considered to withstand winds up to 25 knots, gusts, and light rain, all within a total take-off weight of under 10kg.
In addition, propulsion is set to rely on commercial off-the-shelf (COTS) Li-Po batteries, which have been specified to provide a minimum flight time of 15 minutes with an energy reserve. The payload is designed to be housed in an aerodynamic compartment equipped with an autonomous drop mechanism to ensure reliable delivery without compromising stability.
Key performance targets—such as maximising the thrust-to-weight ratio, minimising drag, and optimising weight distribution—have guided our design to achieve smooth transitions between vertical take-off and forward flight. We have also paid close attention to control responsiveness and endurance to guarantee accurate navigation through waypoints and reliable performance during critical mission phases like payload release.
With the design phase completed, we are now poised to move into prototyping. This next stage will involve transforming our detailed design into physical components and testing them under real-world conditions, ensuring that every aspect of the aircraft meets our stringent performance, safety, and quality standards.
Journey
Our progress so far has been marked by continuous learning and collaboration. After finalising our hybrid VTOL concept, we formed dedicated sub-teams to handle design, manufacturing and prototyping, testing, simulation, autonomous systems, multimedia and sponsorships, and safety. This structure keeps the workflow manageable, allowing each group to focus on a specific area while sharing insights with the wider team during our regular weekly meetings. These sessions not only help us troubleshoot technical issues but also ensure that our vision remains aligned, keeping us motivated and on track.
At the design stage, we began creating CAD models to bring our concepts to life—an iterative process that involves balancing aerodynamic considerations, payload requirements, and overall flight efficiency. As we transition into manufacturing, our workshop is buzzing with activity: 3D-printed components, composite materials, and intricate electronics are coming together under keen supervision. Although we have made significant progress, there is still much to do as we refine and integrate each sub-system in preparation for flight tests.
Challenges and Solutions.
Was this an all-smooth sail?
Developing a sophisticated aircraft from scratch is never straightforward, and we’ve already encountered a fair share of hurdles. One key challenge is perfecting the transition from vertical to horizontal flight—our sub-teams are currently testing different configurations to ensure the aircraft maintains stability and control authority when shifting between these modes.
Balancing flight endurance with payload capacity remains a crucial focus. While larger batteries offer extended flight time, they also add weight. Our propulsion team is working towards fine-tuning the motor efficiencies and battery specifications. Through careful simulations and practical trials, we aim to strike the right compromise between endurance and performance.
We have also devoted considerable effort to streamlining the assembly process. In a competition with extensive mission requirements, technical design is essential. By experimenting with modular components, we aim to minimise assembly steps without compromising the aircraft’s aerodynamic profile or structural integrity.
Results and Impact
Although our UAS is still taking shape, the design phase has already highlighted the importance of synergy between engineering principles, resource management, and effective teamwork. We’ve tested early-stage simulations for autonomous navigation, payload handling, and safe landings, all of which have helped us refine our approach before committing to full-scale manufacturing.
Even at this interim point, this project has had a profound impact on our professional development. It has provided a platform for us to apply theoretical knowledge in a real-world context, enhancing our problem-solving and teamwork skills. Additionally, support from RS has enabled us in acquiring high-quality components and conducting extensive tests. Their support amplifies their deep-rooted commitment to technology and innovation, and empowers the next generation of engineers.
An MSc student in Autonomous Vehicle Dynamics and Control, Abhirva Navalakhe shares his experience with the UIAS Society:
“Being part of the UIAS Society has given me a deeper appreciation of engineering beyond theoretical studies. Working on the hybrid VTOL UAV project has allowed me to face real-world challenges that bridge the gap between academic learning and practical application. This experience is proving invaluable in shaping my career path towards sustainable aerospace innovation. It has not only strengthened my technical abilities but also clarified my professional goals, preparing me for a future where I can contribute meaningfully to the aviation industry.”
Kotireddy Syamala, a research student at Cranfield University talks about taking on the role of Vice President in the UIAS society:
"Joining the UIAS Society as Vice President and Project Manager for the IMechE UAS Challenge has been a transformative experience, allowing me to develop strong leadership, project management, and technical skills. Overseeing a multidisciplinary team has honed my ability to coordinate complex projects, manage timelines, and navigate challenges, all while fostering innovation in UAV design. This role has not only strengthened my problem-solving abilities but also aligned perfectly with my career aspirations in aerospace and engineering, providing hands-on experience that will be invaluable in my professional journey."
Conclusion
Our journey in the IMechE UAS Challenge is far from over; with manufacturing and testing well underway, the next few months promise even more exciting developments as we refine our design and work towards our first full flight trials. We’re eager to see how our UAV will perform under competition conditions and look forward to every milestone along the way.
Follow Our Progress
Stay up to date with our build process, testing highlights, and team insights:
• LinkedIn: https://www.linkedin.com/company/cranfield-imeche-uas-challenge-2025
• Instagram: https://www.instagram.com/uias_society/?igsh=ZXgyejJmY2U2aDFo
Whether you’re a fellow student, an engineering enthusiast, or a potential sponsor, we invite you to join us on this incredible journey of innovation, collaboration, and exploration. Let’s continue unlocking the craft of autonomous flight—together.
Written by Theresa Boateng
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