Design and prototype manufacturing of electric ducted fan (EDF) vtol unmanned aerial vehicle

In this study, the design and production of an unmanned aerial vehicle (UAV) equipped with an electric ducted fan (EDF) propulsion system and vertical take-off and landing (VTOL) capability were carried out. A tilt-based thrust vectoring system was employed to enable transitions between different flight regimes. During the design process, initial requirements were defined, and a conceptual design was created based on these parameters. Subsequently, sketch drawings and computer-aided design (CAD) models of the UAV were prepared. The formulas used in the design calculations were transferred to Microsoft Excel, and various technical data-driven tables and graphs were generated to determine the most suitable design values. The UAV's overall dimensions and basic performance parameters were established. A preliminary study for production was completed, and the CAD drawings were adapted to be manufacturing-ready. Finally, to evaluate the aerodynamic performance of the vehicle, computational fluid dynamics (CFD) analyses were conducted, along with structural strength analyses on critical components. As part of the production phase, mold designs were prepared for the outer body components of the aircraft, and these parts were successfully manufactured using carbon fiber reinforced composite material. The internal structural skeleton components, designed in line with the CAD model, have also been prepared for production; however, the manufacturing and integration of these parts fall outside the scope of this thesis and are planned to be completed post-thesis. In this way, the majority of the essential structural components required for the prototype have been completed, and preparations for the assembly phase have been made. This project was awarded first place in the inaugural year of the "Hangar Campus Innovation Program" organized by Turkish Aerospace Industries (TUSAŞ).