Drone Propeller Thrust Stand
A test stand that turns duct-thruster performance into data.
Summary
Reliable drone propulsion starts with rigorous testing. I developed a thrust stand for a drone-delivery startup to validate yaw-thruster performance. The thrusters operate inside ducts, generating bidirectional thrust, and the stand automates endurance, thermal, and vibration testing — delivering high-fidelity data to improve performance and durability.
The Build
The aerodynamic surfaces began in Siemens NX, modeled to keep flow realistic over the ducts. I built the stand from machined aluminum and steel, using 3D-printed parts to validate airflow before committing to injection-molded propellers.
A motor controller, 6-DOF load cell, and rotary encoders captured torque and thrust, with wind-tunnel runs refining the numbers. From there I defined failure criteria and tuned thruster efficiency through CFD, FEA, and vibration testing.
Results
- A reliable platform for automated, repeatable thrust and endurance validation.
- Data-driven gains in thrust efficiency, duct geometry, and motor performance.
- Designed for DFM/DFA — a clean path from prototype to production.
Specifications
Gallery
