Drone Control System
Custom flight controller PCB, real-time firmware, and a ground-station desktop app for an inspection drone.
What we delivered (snapshot)
- Custom 6-layer flight controller PCB with IMU, barometer, GPS, and 4× ESC outputs.
- Real-time RTOS firmware (Zephyr) with PID attitude control and MAVLink telemetry.
- Carbon fibre frame CAD and motor-mount assemblies for 5-inch inspection platform.
The Challenge
A UAV startup needed a custom flight controller to meet specific payload and telemetry requirements that existing open-source controllers couldn't satisfy without extensive modification. The drone was intended for confined-space inspection (pipes, ducts) where the standard flight envelopes of commercial platforms were too conservative.
The system required deterministic real-time control, a custom telemetry protocol for encrypted ground-station communication, and a carbon fibre airframe sized precisely for door-width duct entry (sub-250 mm).
Constraints
Timeline
20 weeks — Blueprint Sprint + design + prototype
Budget Band
£50k–£75k (PCB + firmware + CAD)
Technical Constraints
- Real-time RTOS — deterministic control loop ≤ 1 ms jitter
- Sub-250 mm airframe width
- Encrypted telemetry link (custom protocol over 915 MHz)
- Drone/UAV scope — within HNES remit
Our Approach
- 1
Fit check & constraints clarification
Confirmed UAV scope (within HNES remit), reviewed payload requirements, and selected Zephyr RTOS as flight-critical RTOS.
- 2
Requirements & acceptance criteria for V1
Defined control loop timing budget, telemetry latency target, and airframe ingress protection for duct operation.
- 3
Architecture & risk register
PCB layer stack for EMI separation, risk register covering RF certification, IMU vibration isolation design.
- 4
Design & build
Simultaneous 6-layer PCB design, Zephyr RTOS firmware, and carbon fibre airframe CAD with custom motor mounts.
- 5
Integration & validation
HITL simulation, bench PID tuning, initial hover tests in controlled environment, telemetry encryption validation.
- 6
Handover package
Full repo, PCB manufacturing pack, airframe drawings, PID tuning log, and recorded handover session.
What We Delivered
- Schematic and 6-layer PCB layout
- Gerbers, BOM, and assembly notes
- EMC pre-scan report and design recommendations
- Zephyr RTOS firmware source (attitude control + telemetry)
- PID tuning log and default parameter set
- MAVLink + custom protocol documentation
- Carbon fibre airframe CAD (sub-250 mm)
- Motor-mount and arm assembly drawings
- DFM notes for CNC carbon fibre cutting
- Ground station desktop app (Electron + React)
- Encrypted telemetry session documentation
- Build and deployment guide
Outcome
"V1 prototype achieved stable hover within the 20-week timeline. Confined-space test confirmed the 248 mm airframe successfully navigated a 260 mm duct entrance. Telemetry link maintained integrity at 200 m range in tests."
Handover
- All hardware and firmware repos
- PCB manufacturing pack
- Airframe CAD files and cutting specs
- Ground station app and encrypted protocol spec
- Recorded handover session
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