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Fixed-Wing Drone Design & Manufacturing
Rating: 4.8 out of 5(3 ratings)
60 students
Created byMicheal Bolzon
Last updated 1/2026
English

What you'll learn

  • Design a complete fixed-wing drone from first principles—from equations to flight
  • Design a complete fixed-wing drone from first principles, starting with mission requirements and aircraft sizing
  • Understand how lift, drag, Reynolds number, and stability affect real aircraft performance, not just theory
  • Size wings, tails, control surfaces, and landing gear for stable, predictable flight
  • Model and simulate aircraft aerodynamics using professional-grade tools to evaluate lift, drag, and pitching moments
  • Iterate and refine a design using aerodynamic data, just like real aircraft designers
  • Select and match motors, propellers, batteries, and electronics for efficient, reliable performance
  • Design and 3D print a flyable aircraft structure, optimized for strength, weight, and manufacturability
  • Configure radio controls, tune handling with rates and expo, and train safely using a flight simulator

Course content

5 sections11 lectures6h 21m total length
  • Fixed-Wing Flight Fundamentals & Aircraft Sizing1:16:25

    In this module, you’ll learn the fundamental physics and engineering principles that govern how fixed-wing aircraft fly—and how to turn those principles into real design decisions.

    We’ll begin by building an intuitive understanding of lift, drag, and wing aerodynamics, then break drag down into its individual components so you can see exactly where performance is gained or lost.

    From there, you’ll learn how aircraft remain balanced in flight by understanding pitching moments, stability, trim, and center of gravity placement—critical concepts for designing drones that actually fly as expected.

    Finally, we’ll move from theory to application by introducing thrust-to-weight ratio, wing loading, stall speed, and other key performance constraints. Using these tools, you’ll perform your first real aircraft sizing exercise, estimating the weight and wing area of a fixed-wing drone based on its mission requirements.

    By the end of this module, you will be able to:

    • Explain how lift and drag are generated on a wing

    • Identify and quantify the major components of drag

    • Understand pitching moments, stability, and aircraft balance

    • Estimate thrust and power requirements

    • Size a fixed-wing aircraft to determine its weight and wing area

    This module forms the foundation for all aerodynamic design, performance analysis, and manufacturing work that follows in the course.

  • Conceptual Aircraft Modeling & Aerodynamic Analysis36:50

    In this module, you’ll learn how to turn your initial aircraft sizing calculations into a real, analyzable fixed-wing design using professional-grade conceptual modeling tools.

    You’ll begin by understanding how conceptual aircraft models are used in real aerospace design workflows, and why they are essential for making fast, informed design decisions before detailed CAD or manufacturing.

    Step by step, you’ll build a fully parametric fixed-wing aircraft model, defining the wing, fuselage, and tail geometry while ensuring reference areas, mass properties, and center of gravity are set correctly.

    Once the model is complete, you’ll prepare it for aerodynamic simulation and run analyses to generate lift, drag, and pitching moment data. You’ll then learn how to interpret these results, compare them against your hand calculations from Module 1, and use the data to iterate and improve the design.

    By the end of this module, you will be able to:

    • Build a parametric fixed-wing aircraft model

    • Configure an aircraft for aerodynamic simulation

    • Run lift, drag, and moment analyses

    • Validate simulation results against first-principles estimates

    • Iterate an aircraft design to improve aerodynamic performance

    This module bridges the gap between theoretical aircraft sizing and practical aerodynamic analysis, forming a critical step toward detailed design and manufacturing.

  • Reynolds Number Effects & Wing Design for Fixed-Wing Drones37:18

    In this module, you’ll learn how the Reynolds number fundamentally affects the aerodynamic performance of fixed-wing drones—and how to design wings and tail surfaces that actually work at small scales.

    We’ll start by developing a clear, intuitive understanding of what the Reynolds number is and why it plays such a critical role in low-speed, small-scale aircraft. You’ll see how the Reynolds number influences lift, drag, stall behavior, and overall efficiency in ways that are often overlooked in traditional aircraft design.

    From there, you’ll apply these principles directly to the design of your aircraft’s wing, learning how to select wing area, aspect ratio, and planform shape based on performance goals and operational constraints.

    You’ll then move on to tail design, where you’ll learn how to size and position horizontal and vertical tail surfaces to ensure stability, control, and predictable handling—without unnecessary drag or weight.

    By the end of this module, you will be able to:

    • Explain what the Reynolds number is and why it matters for fixed-wing drones

    • Predict how the Reynolds number affects lift, drag, and stall behavior

    • Design a wing that is appropriate for low-speed, small-scale flight

    • Size horizontal and vertical tail surfaces for stability and control

    • Make informed aerodynamic tradeoffs for real-world UAV designs

    This module gives you the aerodynamic insight needed to design efficient, stable fixed-wing drones—especially at the low Reynolds numbers where many designs fail.

Requirements

  • No aerospace background required
  • Familiarity with basic spreadsheets is helpful, but all calculations are explained step by step
  • A willingness to learn and experiment with aircraft design concepts

Description

Design, Simulate, and Build Your Own Fixed-Wing Drone — From First Principles to Flight

Have you ever wanted to design a fixed-wing aircraft that actually flies the way you expect — not through trial and error, but using real engineering principles?

This course takes you through the complete fixed-wing aircraft design process, starting from fundamental aerodynamics and ending with a 3D-printed, flyable aircraft. You’ll learn not just what works, but why it works — and how to apply those principles to your own designs.

We begin with the physics of flight: lift, drag, stability, and aircraft sizing. You’ll learn how to balance an aircraft, predict its performance, and make design decisions using equations and spreadsheets instead of guesswork.

From there, you’ll move into aerodynamic modeling and simulation, where you’ll build aircraft concepts and evaluate their lift, drag, and pitching moments using professional-grade, free software. You’ll see how real aerodynamic data informs design choices and how to iterate toward better performance.

Next, we focus on stability, control, and handling, covering moments, center of gravity placement, control surface sizing, landing gear design, and stall behavior. These lessons ensure your aircraft is not only flyable, but stable and forgiving.

You’ll then learn how to select and integrate real aircraft systems, including motors, propellers, batteries, servos, radios, and power systems. You’ll understand how each subsystem interacts and how to avoid common failures that lead to crashes.

Finally, the course bridges design and reality with 3D-printed aircraft manufacturing. You’ll learn how to design airframes specifically for 3D printing, optimize strength and weight, choose materials, and produce parts that survive real flight loads. You’ll also learn how to configure your radio controls, tune handling with rates and expo, and train safely using a free flight simulator before flying.

By the end of this course, you won’t just understand fixed-wing aircraft — you’ll have a complete, repeatable process for designing, building, and flying your own airplanes.

What Makes This Course Different

  • Focuses on real aircraft design, not kits or guesswork

  • Teaches first-principles engineering in a practical, accessible way

  • Uses free, professional-grade tools

  • Connects aerodynamics, systems, manufacturing, and flight into one workflow

  • Designed for engineers, students, makers, and serious hobbyists

Who This Course Is For

  • Anyone who wants to design and build a fixed-wing drone from scratch

  • Engineers and students seeking practical aircraft design experience

  • RC pilots who want to understand why aircraft behave the way they do

  • Makers interested in 3D-printed, functional aircraft

No prior aircraft design experience is required — all concepts are explained step by step.

Who this course is for:

  • Beginners with no prior aircraft design experience—all concepts and tools are explained step by step
  • Anyone who wants to design and build their own fixed-wing drone, from concept to flight
  • Engineers, students, and makers who want a practical, hands-on approach to aircraft design
  • Drone and RC pilots and UAV enthusiasts who want to understand why aircraft fly the way they do
  • Hobbyists frustrated by trial-and-error designs who want a structured, engineering-based workflow
  • Aerospace or mechanical engineering students looking for real-world fixed-wing design experience
  • Entrepreneurs and startups interested in developing custom fixed-wing UAVs
  • 3D printing enthusiasts who want to create functional, flyable aircraft