DIY Drone

During the summer of 2020, I built a custom quadcopter from scratch for FPV flying and aerial photography. Below is a concise breakdown of the build.

Overview

A complete DIY quadcopter build featuring custom 3D-printed components, brushless motors, and FPV capabilities. This project explores the fundamentals of drone aerodynamics, flight control systems, and radio communications.

Specifications

• Frame: Custom 250mm carbon fiber/3D-printed hybrid
• Motors: 2300KV brushless outrunners
• Flight Controller: F4 with BetaFlight firmware
• Camera: 800TVL FPV camera + GoPro mount
• Battery: 4S 1500mAh LiPo
• Flight Time: ~12-15 minutes
• Weight: 485g (without battery)

Build Process

Frame Assembly

I started with a carbon-fiber base plate for rigidity and vibration damping. The arms are 3D-printed in reinforced PLA to balance weight and strength.

Electronics Integration

The flight controller runs BetaFlight for precise control and tuning. I wired a 4-in-1 ESC to minimize clutter and soldered XT60 connectors for quick battery swaps.

Wiring diagram:

Battery → PDB → FC (5V) → Receiver
       ↓
       ESC → Motors (x4)
       ↓
       FPV Camera → VTX → Antenna

Configuration & Tuning

PID tuning in BetaFlight took several sessions to get smooth, responsive flight. Key settings:

• P: 45, I: 70, D: 32 (roll/pitch)
• RC Rate: 1.8, Expo: 0.15
• Camera Angle: 35°

Test Flights

Initial flights showed oscillation at high throttle; I resolved this by reducing P gains and checking motor balance. After tuning, the quadcopter flew stably and responsively.

Here is a short demo video — let’s see it in action:

Key Learnings

What worked well: Hybrid frame design saved weight while maintaining strength. BetaFlight’s OSD is invaluable for real-time telemetry.

Challenges: Motor vibrations affecting FPV feed required dampening with rubber grommets. Soldering the 4-in-1 ESC in tight quarters was tricky.

Next iteration: Better antenna placement, GPS module for position hold, and lighter frame design.

Parts List