A design-and-make project focused on developing a model electric VTOL vehicle from brief analysis through concept development, manufacturing, and evaluation.
The project began by extracting key constraints from the brief: an automatically opening door, a fuselage compartment, seating for two, minimum four turbines, fixed size limits, and low-voltage electrical power.
From these, secondary design questions were derived: cockpit visibility, passenger access, door actuation packaging, rotor arrangement, and how to preserve aerodynamic intent despite model-scale manufacturing limits.
Existing eVTOL architectures were reviewed to compare trade-offs between stability, efficiency, and mechanical complexity. Concept work considered fixed-rotor configurations, vectored thrust systems, and drivetrain transfer ideas for distributing power.
Door mechanisms were also explored in parallel, including lead-screw based linear motion to meet the automatic opening requirement in a compact, model-friendly format.
The selected concept combined aerodynamic bodywork with workshop-ready methods. A lofted CAD hull was used to generate mold geometry for vacuum forming. Trial parts exposed heat-related warping in early tooling and required material/process changes.
Design-for-manufacture updates included improved mold support, release taper on vertical surfaces, and surface preparation to reduce print layer transfer onto formed parts.
Body-to-structure joining was resolved with an internal support rim and mechanical fastening strategy. Window and windshield shaping were tested separately to improve conformity against curved geometry.
Where seamless transitions were difficult between formed components, visual detailing was used to make seams intentional and coherent with the design language of the final model.
Testing focused on process reliability, fit quality, and assembly repeatability. Iteration from failed or imperfect trials directly informed tooling changes, heating windows, and finishing methods.
Final evaluation considered both technical compliance with the brief and the quality of manufacture and documentation expected in a complete engineering portfolio.
The portfolio concludes with production drawings and planning documents used to communicate dimensions, manufacturing sequence, and assembly intent across the full build.
This Model EVTOL project demonstrates an end-to-end engineering workflow: interpreting constraints, evaluating alternatives, selecting a manufacturable concept, and refining output through iterative testing.
The final outcome emphasizes practical decision-making and process control as much as final appearance, showing how design intent can be translated into a robust physical model under real workshop conditions.