INDUSTRIAL INTERNSHIP REPORT

ON
FIELD OF MANUFACTURING AND
DESIGNING IN UAV
Submitted by
BHARATHI S

In partial fulfillment for the award of the degree

of

BACHELOR OF ENGINEERING

in

AERONAUTICAL ENGINEERING

ADHIYAMAAN COLLEGE OF ENGINEERING

ANNA UNIVERSITY:CHENNAI 600 025

NOVEMBER 2025
 ANNA UNIVERSITY : CHENNAI -6000 025

BONAFIDE CERTIFICATE

This is to certified that MISS BHARATHI S(6176AC23UAE002) from the V semester [Link]
Engineering, has completed the industurial intership “Field of manufacturing and designing in UAV”
during the period 11 AUGUST 2025 TO 29 AUGUST 2025 at AAKASH AEROSPACE PVT LMT
and the report has been submitted to Anna University which is the partial fulfillment for awarding
[Link] Enginnering Degree

SIGNATURE SIGNATURE
[Link],M.E [Link] KUMAR,M.E,Ph.d
SUPERVISOR AND ASSISTANT PROFESSOR HEAD OF THE DEPARTMENT
Department of Aeronautical Engg Department of Aeronautical Engg
Adhiyamaan College of Engineering Adhiyamaan College of Engineering
(Autonomous) (Autonomous)
Dr.M.G.R Nagar, Dr.M.G.R Nagar,
Hosur-635 109. Hosur-635 109.

Submitted for viva-voce examination held on _________________ at Adhiyamaan College of

Engineering (Autonomous), Hosur.

INTERNAL EXAMINER EXTERNAL EXAMINER

 ACKNOWLEDGEMENT

First and foremost, I express my gratitude to the Almighty, the magnificent Architect of the
Universe, for bestowing upon me the ability to successfully complete my Bachelor of
Engineering and project.
I extend my heartfelt appreciation to Dr R. RADHAKRISHNAN, M.E., PhD, the principal
of Adhiyamaan College of Engineering Hosur, for endorsing my internship.

I am thankful to Dr. SENTHIL KUMAR, PhD , Professor and Head of the Department of
Aeronautical Engineering, for providing the necessary facilities that led to the successful
execution of this internship.

I extend our sincere thanks to internal supervisor, Mrs B RAJESWARI, M.E., Assistant
Professor, Department of Aeronautical, Adhiyamaan College of Engineering, Hosur, for his
great support and significant input in completing our internship.

I extend my thanks to our internship mentor, Mr. K. SARAVANAN, Chairman Managing

Director of AAKASH AEROSPACE PRIVATE LIMITED –for his valuable guidance
to complete the internship successful.

I wish to acknowledge our parents for their unwavering support in all facts of our lives. I
hold deep affection and respect for their sacrifices, which have greatly contributed to my growth
and well-being.
CERTIFICATE
 TABLE OF CONTENT

CHAPTER TITLE PAGE

NO NO
LIST OF ABBREVATION i
LIST OF FIGURE ii
LIST OF TABLE iii
ABSTRACT 1
1 INTRODUCTION 2
2 COMPANY PROFILE 3
2.1 INTRODUCTION TO AAKASH AEROSPACE 3
2.2 VISION AND MISSION 3
2.2.1 Vision 4
2.2.2 Mission 4
2.3 CORE AREAS OF EXPERTISE 4
2.3.1. UAV Design and Development 4
2.3.2 Avionics and Control Systems 4
2.3.3 Manufacturing and Prototyping 5
2.3.4 Research and Development (R&D) 5
2.3.5 Training and Internships 5
2.4 INDUSTRY CONTRIBUTION 6
2.5 FACILITIES AND INFRASTRUCTURE 6
2.6 IMPORATANCE OF INTERSHIP AT AAKASH 7
3 INTERSHIP OBJECTIVES 8
3.1 TECHNICAL KNOWLEDGE ENHANCEMENT 8
3.2 SKILL DEVELOPMENT 8
3.3 RESEARCH AND ANALYTICAL EXPOSURE 9
3.4 PROFESSIONAL AND INDUSTRY SKILLS 9
3.5 PERSONAL DEVELOPMENT 9
3.6 INTEGRATION OF KNOWLEDGE AND PRACTICAL APPLICATION 10
4 METHODOLOGY 11
 4.1 INTRODUCTION 11
4.2 THEORETICAL LEARNING 12
4.3 SOFTWARE AND TOOL TRAINING 12
4.4 PRACTICAL WORK AND HANDS-ON EXPOSURE 13
4.5 TESTING,EVALUTION AND REFLECTION 13
4.6 METHODOLOGY FLOWCHART 14
5 TRAINING AND SOFTWARE EXPOSURE 15
5.1 INTRODUCTION 15
5.2 CAD AND 3D MODELLING TRAINING 15
5.2.1 Part Modelling 15
5.2.2 Assembly Design 15
5.2.3 Technical Drawings 15
5.2.4 Design Optimization 15
5.3 3D PRINTING AND MANUFACTURING 16
5.4 AERODYNAMICS ANALYSIS TOOLS 16
5.5 ELECTRONICS AND UAV SYSTEMS TRAINING 17
5.6 COMPOSITE MATERIAL TRAINING 18
5.7 SOFTWARE EXPOSURE 18
6 PROJECT WORK(DAYWISE ACTIVITIES) 18
6.1 DAY 1 – DATASET COLLECTION & LITERATURE STUDY 19

6.2 DAY 2 – AIRFOIL SELECTION & VTOL UAV CONCEPT STUDY 19

6.3 DAY 3 – SOLDERING PRACTICE AND ELECTRONIC ASSEMBLY 19
6.4 DAY 4 – AERODYNAMIC CALCULATIONS (LIFT, DRAG,THRUST) 20

6.5 DAY 5 – WIRING AND ESC INTEGRATION 20

6.6 DAY 6 – FRAME CONSTRUCTION OF FLYING WING 20

6.7 DAY 7 – FPV DRONE STUDY AND SOLIDWORKS TRAINING 21

6.8 DAY 8 – UAV PART DESIGN IN SOLIDWORKS 21

6.9 DAY 9 – COMPOSITE PROCESS & CONTROL PANEL 21

INTEGRATION
6.10 DAY 10 – ASSEMBLY AND INITIAL FLIGHT TESTING 21
 6.11 DAY 11 – AIRCRAFT MODELING & 3D PRINTING PRACTICE 21
6.12 DAY 12 – GPS MODULE AND ADVANCED WIRING 21
6.13 DAY 13 – STRUCTURAL ASSEMBLY AND SYSTEM 22
INTEGRATION
6.14 DAY 14 – DRONE TECHNOLOGY & PILOT LICENSE 22
AWARENESS
7 LEARNING OUTCOMES 23
7.1 TECHNICAL SKILLS 23
7.2 PRACTICAL EXPOSURE 23
7.3 PROFESSIONAL SKILLS 24
7.4 INDUSTRY AWARENESS 24
7.5 PERSONAL DEVELOPMENT 25
8 CONCLUSION 26-28
9 FUTURE SCOPE 29-30
10 REFERENCES 31
11 APPENDICES 32
 LIST OF ABBREVIATION

LETTER ABBREVIATION
UAV UNMANNED AERIAL VEHICLE
CAD COMPUTER AIDED DESIGN
ESC ELECTRONIC SPEED CONTROLLER
VTOL VERTICAL TAKE OFF LANDING
GPS GLOBAL POSITIONING SYSTEM
DGCA DIRECTOR GENERAL OF CIVIL AVIATION

i
 LIST OF FIGURE

FIGURE NO DESCRIPTION PAGE NO

4.1 SOLIDWORKS WING 3D MODEL 12

5.1 GRAPH OF NACA 0012 17

ii
 LIST OF TABLE

TABLE NO DESCRIPTION PAGE NO

5.1 SOFTWARE TOOL PURPOSE 18

iii
 ABSTRACT

This report presents a comprehensive account of my internship training at Aakash Aerospace,

where I was exposed to the multifaceted world of Unmanned Aerial Vehicle (UAV) technologies.
The internship was designed to bridge the gap between academic knowledge and practical
aerospace industry practices by integrating theoretical study, software training, and hands-on
technical work. Over the course of the internship, I received structured training in aerodynamics,
airfoil selection, and UAV flight principles, including detailed calculations of lift, drag, and thrust
for commonly used airfoils such as NACA0012 and MH60. In parallel, I gained significant
exposure to CAD modeling using SolidWorks, where I designed UAV components including
fuselage sections, wing ribs, and structural assemblies. These digital models were later translated
into prototypes using 3D printing technology, which provided a clear understanding of how
conceptual designs are converted into tangible UAV parts.

A major focus of the internship was on UAV electronics integration. I practiced soldering
techniques, wiring of ESCs, servo motor connections, and GPS module integration with the flight
controller. Special attention was given to wiring practices, system calibration, and testing of
electronic subsystems. I was also introduced to composite material processing, learning how
lightweight yet strong structures can be fabricated for UAV [Link], this internship
enhanced my technical skills (CAD, soldering, electronics, UAV assembly), practical exposure
(composite processing, 3D printing, flight testing), and professional competencies (teamwork,
communication, and report preparation). The knowledge and skills acquired through this program
have provided me with a strong foundation in UAV design and applications, while also inspiring
me to further specialize in aerospace systems and unmanned technologies.

1
 CHAPTER 1
INTRODUCTION

The aerospace industry has evolved into one of the most dynamic and technologically advanced
sectors of the modern world. It plays a pivotal role in national defense, space exploration,
commercial aviation, disaster management, and remote sensing applications. Within this vast
domain, Unmanned Aerial Vehicles (UAVs) have emerged as a revolutionary technology,
enabling a wide spectrum of missions that were previously considered either impossible or
extremely costly.

Internships in aerospace organizations like Aakash Aerospace are specifically designed to

provide this bridge. They allow students to gain practical exposure in areas such as airfoil selection,
aerodynamic calculations, soldering and wiring of UAV electronics, CAD modeling using
SolidWorks, 3D printing for prototyping, composite material processing, and UAV flight testing.
By participating in these tasks, students not only enhance their technical competencies but also
learn the value of teamwork, documentation, time management, and adherence to industrial
standards.

The internship undertaken at Aakash Aerospace was structured to cover both theoretical
understanding and hands-on experience. The program began with a review of existing UAV
technologies, dataset analysis, and literature survey on aerodynamics. This was followed by
technical training in software such as SolidWorks CAD and Bambu Studio for 3D printing,
enabling me to design and visualize UAV components. The training further extended to practical
workshops on soldering, wiring, ESC calibration, GPS integration, and frame construction of
UAVs. This comprehensive training helped me build a solid foundation in aerospace design and
enhanced my confidence in handling real-world engineering challenges.

2
 CHAPTER 2
COMPANY PROFILE

2.1 Introduction to Aakash Aerospace

Aakash Aerospace is a pioneering aerospace organization in India, committed to advancing the

field of aeronautical engineering, drone technology, and aerospace training. Established with the
vision of providing high-quality solutions in unmanned aerial vehicles (UAVs), defense
applications, industrial inspection, and academic training, the company has built a strong
reputation for combining innovation with practical implementation.

In today’s rapidly evolving aerospace sector, organizations like Aakash Aerospace play a
critical role by bridging the gap between theoretical research and real-world applications. The
company not only designs and develops UAV systems but also provides structured internship and
training programs to empower the next generation of aerospace engineers. With a focus on
research, prototyping, and hands-on skill development, Aakash Aerospace contributes
significantly to India’s growing aerospace and defense ecosystem.

2.2 Vision and Mission

2.2.1Vision
To become a leading force in the aerospace and UAV industry by fostering innovation,
promoting indigenous technological development, and training skilled engineers who can meet
global standards .

2.2.2 Mission

 To design and manufacture UAVs for multi-sectoral applications such as defense,

surveillance, disaster management, agriculture, mapping, and logistics.
 To create a learning environment where students and professionals gain practical exposure
to aerospace engineering tools, materials, and methodologies.

3
  To build partnerships with academic institutions, research labs, and industries to drive
collaborative innovation.
 To promote “Make in India” aerospace solutions, reducing dependence on foreign imports
and boosting indigenous capabilities.

2.3 Core Areas of Expertise

Aakash Aerospace operates in multiple domains of aerospace engineering, with a strong

emphasis on UAV development and training. Its expertise can be categorized into the following
areas

2.3.1. UAV Design and Development

The company specializes in designing drones with different configurations such as

 Quadcopters and Hexacopters for aerial photography, surveillance, and payload delivery.
 Flying Wing UAVs for aerodynamic efficiency and long endurance missions.
 Fixed-Wing Drones for mapping and surveying applications.
 Hybrid UAVs combining rotary and fixed-wing capabilities.

The design process integrates aerodynamic analysis, CAD modeling, material selection, 3D
printing, and assembly to create optimized UAV platforms.

2.3.2 Avionics and Control Systems

Modern UAVs rely heavily on advanced avionics, and Aakash Aerospace focuses on

 Integration of flight controllers, GPS modules, and telemetry systems.

 Programming of autonomous missions using ground control software.
 Calibration of Electronic Speed Controllers (ESCs), motors, and sensors.
 Development of AI-assisted payloads such as human detection cameras and obstacle
avoidance modules.

4
2.3.3 Manufacturing and Prototyping

The company is equipped with facilities for

 3D printing of UAV components using advanced software like Bambu Studio.

 SolidWorks CAD modeling for precision design.
 Composite material processing (carbon fiber, fiberglass) for lightweight structures.
 Assembly workshops for soldering, wiring, and integration of UAV frames.

This manufacturing infrastructure allows students and engineers to gain hands-on knowledge of
concept-to-prototype development.

2.3.4 Research and Development (R&D)

R&D forms the backbone of Aakash Aerospace’s operations. Current research areas include

 Aerodynamic optimization of airfoils and wing designs.

 Use of artificial intelligence in UAV detection and tracking systems.
 UAV-based logistics and medical kit delivery systems.
 Development of long-range communication using LoRa technology.
 Sustainable solutions such as fuel cell-powered UAVs and solar-assisted drones.

2.3.5 Training and Internships

One of the flagship services of Aakash Aerospace is its industrial training and internship programs.
These are carefully designed to meet academic requirements while providing exposure to industry-
standard practices. The training modules include

 Introduction to aerospace fundamentals.

 Hands-on practice with SolidWorks CAD, airfoil analysis, and UAV simulations.
 Practical workshops on soldering, wiring, GPS calibration, and drone assembly.
 Exposure to 3D printing and prototype development.
 Daywise project work, ensuring structured and progressive learning.
5
Through these programs, students acquire not only technical skills but also teamwork, leadership,
and communication abilities that are essential in professional aerospace careers.

2.4 Industry Contributions

Aakash Aerospace has contributed significantly to the aerospace community through

 Collaborations with academic institutions to conduct UAV workshops and research

projects.
 Participation in aerospace exhibitions and competitions, showcasing indigenous UAV
designs.
 Development of cost-effective drone platforms suitable for Indian conditions, particularly
in agriculture and defense surveillance.
 Contribution to DGCA drone awareness programs, spreading knowledge about UAV
regulations in India

2.5 Facilities and Infrastructure

The company maintains modern infrastructure to support both R&D and training activities

 Design Studio – Equipped with CAD and simulation software (SolidWorks, ANSYS,
XFLR5).
 Prototyping Lab – Housing 3D printers, soldering stations, and electronic assembly setups.
 Aerodynamics Workshop – For testing airfoils, UAV models, and control surfaces.
 Flight Testing Ground – A safe, DGCA-compliant field for testing UAVs.
 Training Classrooms – Equipped with multimedia facilities for interactive learning.
 This integrated setup ensures that students experience the complete engineering cycle —
from design to manufacturing to testing.

6
2.6 Importance of the Internship at Aakash Aerospace

The internship program at Aakash Aerospace is not just about observing but actively participating
in ongoing projects. It provide

 A professional environment where students can apply academic knowledge.

 Access to real projects, such as UAV design, dataset analysis, and flight integration.
 Mentorship from experienced engineers, who guide interns step by step.
 An opportunity to document and present work, preparing students for industry-level
reporting.

By the end of the internship, students gain

 Technical proficiency in CAD, soldering, wiring, 3D printing, and UAV assembly.

 Problem-solving skills through daywise challenges.
 Industry awareness regarding DGCA regulations, UAV classifications, and market trends.
 A strong foundation for future careers in aerospace, defense, or UAV startups.

7
 CHAPTER 3
INTERNSHIP OBJECTIVES

The primary aim of the internship at Aakash Aerospace was to bridge the gap between
theoretical knowledge gained in the classroom and its practical application in real-world aerospace
engineering projects. The internship provided comprehensive exposure to UAV design,
aerodynamics, electronics integration, CAD modeling, composite processing, and flight testing.
The objectives of this internship can be elaborated as follows

3.1 Technical Knowledge Enhancement

 To understand the principles of UAV design, including structural layouts, airframe

dynamics, and weight optimization.
 To study the aerodynamics of UAVs, including airfoil selection, lift, drag, and thrust
calculations for efficient flight performance.
 To explore electronic systems integration such as ESCs, servomotors, GPS modules, and
flight controllers in UAVs.
 To gain practical exposure to composite materials and understand their application in
lightweight and strong UAV structures.
 To familiarize with 3D printing technology for rapid prototyping and iterative UAV design
improvements.

3.2 Skill Development

 To develop proficiency in CAD modeling using SolidWorks, including part design,

assemblies, and mechanical detailing for UAV components.
 To acquire hands-on skills in soldering, wiring, and system integration for electronics and
UAV flight systems. To learn assembly techniques, balancing UAV structures for stability
and flight efficiency.
 To learn assembly techniques, balancing UAV structures for stability and flight efficiency.

8
  To learn assembly techniques, balancing UAV structures for stability and flight efficiency.
 To perform flight testing, observing UAV behavior and validating design assumptions in
real-world conditions.

3.3 Research and Analytical Exposure

 To conduct literature reviews and analyze airfoil performance, VTOL designs, and UAV
trends for better design decision-making.
 To apply aerodynamic principles in simulations and calculations to optimize UAV
performance.
 To experiment with composite lamination, structural reinforcement, and weight
distribution to enhance UAV functionality.

3.4 Professional and Industry Skills

 To understand project management and workflow in a professional aerospace organization.

 To develop teamwork, communication, and problem-solving skills by collaborating with
mentors, engineers, and peers.
 To practice technical reporting, documentation, and presentation skills, crucial for
professional engineering roles.
 To gain awareness of industry standards, UAV regulations, and pilot license requirements
to ensure compliance and operational safety.

3.5 Personal Development

 To improve critical thinking and analytical skills through real-time problem-solving and
design iterations.
 To enhance time management and responsibility while executing daily project tasks and
meeting deadlines.
 To cultivate a disciplined, professional attitude and adaptability in a dynamic engineering
environment.

9
3.6 Integration of Knowledge and Practical Application

 To combine classroom theory with practical implementation, from airfoil analysis and
CAD modeling to UAV assembly and flight testing.
 To identify design limitations, troubleshoot UAV systems, and propose innovative
solutions for aerospace challenges.
 To prepare for future aerospace projects, research, and potential career opportunities in
UAV technologies and aerospace engineering.

10
 `CHAPTER 4
METHODOLOGY

The methodology followed during the internship at Aakash Aerospace was designed to provide
a comprehensive understanding of UAV development, integrating theoretical knowledge, practical
skills, and professional practices. The approach combined structured learning, hands-on training,
and project-based activities to ensure a holistic experience.

4.1 Overview of the Methodology

The internship methodology can be broadly categorized into four key phases:

1. Theoretical Learning – Understanding the principles and fundamentals of UAV design

and aerospace engineering.
2. Software and Tool Training – Developing proficiency in CAD, simulation, and 3D
printing software.
3. Practical Work and Hands-On Exposure – Performing assembly, electronics
integration, and composite material processing.
4. Testing, Evaluation, and Reflection – Conducting flight tests, evaluating performance,
and receiving mentor feedback.

These phases were carried out in a structured daily schedule to ensure progressive learning.

4.2 Theoretical Learning

The theoretical component provided a foundation for all practical work. It included:

 Literature Review and Research- Studied academic papers, UAV design manuals, and
airfoil databases to understand aerodynamics, structural design, and VTOL systems.

11
  Lectures and Discussions- Attended sessions on UAV classifications, flight principles,
DGCA regulations, safety protocols, and emerging technologies in drone systems.
 Airfoil and Aerodynamic Studies- Learned to perform lift, drag, and thrust
calculations, and analyzed NACA airfoils for suitability in fixed-wing UAVs and flying
wing designs.
 Structural and Material Analysis- Studied composite materials, 3D printing materials,
and their mechanical properties for lightweight UAV construction.

This phase helped translate conceptual knowledge into actionable design decisions for UAV
components.

4.3 Software and Tool Training

Proficiency in modern engineering tools is essential for UAV design. The internship included:

 SolidWorks CAD:
o Modeled UAV components such as wing ribs, fuselage, and VTOL assemblies.

Figure 4.1 SOLIDWORKS WING 3D MODEL

o Created assemblies for complete UAV structures, including mounting points for
electronics and servos.
o Generated detailed technical drawings for fabrication and 3D printing.

12
  3D Printing Software (Bambu Studio)
o Prepared CAD models for additive manufacturing.
o Learned slicing, support generation, and optimization for weight reduction.
 Aerodynamic and Flight Simulation Tools
o Simulated airflow over wings and control surfaces.
o Performed theoretical calculations to validate predicted lift, drag, and stability.

4.4 Practical Work and Hands-On Exposure

Hands-on experience formed the core of the internship. Key activities included:

 Soldering and Wiring- Learned to solder connections, integrate ESCs, connect servos,
and wire GPS and flight controllers.
 Composite Material Processing-Practiced lamination techniques, cured UAV parts using
fiberglass or carbon fiber, and ensured proper weight distribution.
 3D Printing and Prototyping-Printed UAV components, checked dimensional accuracy,
and performed iterative design adjustments.
 Assembly of UAV Structures- Assembled flying wing and VTOL UAVs, ensuring
structural balance, proper alignment, and functionality.
 GPS Module Integration- Connected navigation modules and validated signal reception
for autonomous flight support.

Each practical activity was supervised, and mentor feedback was incorporated to improve skills
and understanding.

4.5 Testing, Evaluation, and Reflection

Evaluation was conducted to measure design efficiency, functional performance, and learning
outcomes

13
  Ground Testing- Checked the structural integrity, electronics connectivity, and control
surface movements before flight.
 Flight Testing- Conducted controlled low-altitude flights to observe UAV stability,
responsiveness, and payload handling.
 Data Analysis- Compared observed flight performance with theoretical predictions from
aerodynamic calculations.
 Reflection and Feedback- Maintained a daily log of activities, challenges, and learning
outcomes. Received mentor feedback to identify areas for improvement.

This phase ensured continuous learning, problem-solving, and validation of engineering

principles in real-world UAV operations.

4.6 Methodology Flowchart

Step 1 – Literature Review and Theoretical Study

↓
Step 2 – CAD Modeling and Software Training
↓
Step 3 – Electronics Integration and Composite Processing
↓
Step 4 – UAV Assembly and Pre-Flight Checks
↓
Step 5 – Flight Testing and Data Analysis
↓
Step 6 – Mentor Feedback and Documentation

14
 CHAPTER 5
TRAINING AND SOFTWARE EXPOSURE

The internship at Aakash Aerospace provided extensive exposure to various software tools,
engineering practices, and hands-on technical skills essential for UAV design and development.
This chapter elaborates on the training modules, software platforms, and practical exercises
undertaken during the internship.

5.1 Training Overview

The training program was structured to provide a progressive learning experience, covering

1. Theoretical understanding of UAV systems and aerodynamics

2. Software proficiency for design and simulation
3. Hands-on training in electronics, composite materials, and UAV assembly
4. Flight testing and evaluation

This approach ensured that interns could apply theoretical concepts practically, integrate software
tools with real hardware, and develop problem-solving skills in UAV design and development.

5.2 CAD and 3D Modeling Training

SolidWorks CAD was the primary software tool for designing UAV components. Training
included

 Part Modeling
o Created UAV structural components such as wing ribs, fuselage, tail assemblies,
and landing gears.
o Applied parametric modeling to allow easy modification of dimensions and
features.

15
  Assembly Design
o Assembled all UAV components digitally to check fitment, alignment, and inter-
component clearances.
o Simulated mechanical movement of control surfaces and servomotors within
assemblies.
 Technical Drawings
o Generated detailed engineering drawings for fabrication and 3D printing.
o Annotated dimensions, tolerances, and material specifications.
 Design Optimization
o Iteratively modified UAV components for weight reduction, structural strength,
and aerodynamic efficiency.

5.3 3D Printing and Additive Manufacturing

Bambu Studio and other 3D printing tools were used for rapid prototyping

 Model Preparation Converted SolidWorks models to STL files and prepared them for
slicing.
 Slicing and Support Generation Configured print settings, supports, and infill for structural
stability.
 Material Selection Worked with PLA, ABS, and carbon fiber-reinforced filaments to
fabricate UAV components.
 Prototype Fabrication Printed wings, fuselage parts, and custom mounts for electronics.

5.4 Aerodynamic Analysis Tools

Understanding airflow, lift, drag, and stability is critical in UAV design:

 Airfoil Analysis Calculated lift and drag coefficients for NACA series airfoils (e.g.,
NACA0012, MH60).

16
 FIGURE 5.1 GRAPH OF NACA 0012

 Simulation Exercises Performed basic flow analysis to evaluate aerodynamic efficiency.

 Flight Performance Predictions thrust requirements, maximum speed, and optimal angle of
attack.

5.5 Electronics and UAV Systems Training

Hands-on exposure to UAV electronics was a key component of the internship

 Soldering and Wiring Practiced secure connections for ESCs, motors, and flight
controllers.
 ESC and Motor Calibration Configured Electronic Speed Controllers for optimal motor
performance.
 Servomotor Integration Installed and tested control surfaces, ensuring correct range of
motion.

17
  GPS and Flight Controller Setup Integrated GPS modules and validated navigation
functionality.
 Battery and Power Management Learned safe handling and connection of LiPo batteries,
voltage monitoring, and balancing.

5.6 Composite Material Training

Composite materials are critical for lightweight UAV structures

 Material Handling Worked with fiberglass and carbon fiber sheets, resins, and curing
processes.
 Lamination Techniques Learned proper layering, curing, and finishing to achieve strong,
lightweight UAV parts.
 Structural Testing Evaluated strength and rigidity of laminated components.

5.7 Software Exposure

Software / Tool Purpose Learning Outcome

SolidWorks CAD UAV part modeling & Parametric design, assembly simulation,
assembly technical drawings
Bambu Studio 3D printing & STL preparation, slicing, material handling,
prototyping prototype fabrication
Flight Controller ESC calibration, GPS UAV system setup, navigation validation,
Software integration motor control
Aerodynamic Tools Lift, drag, and thrust Airfoil analysis, aerodynamic optimization,
calculations flight prediction
Composite Material Laminating UAV parts Lightweight structural design, strength
Kits testing, finishing

TABLE 5.1 SOFTWARE TOOL PURPOSE

18
 CHAPTER 6
PROJECT WORK (Daywise Activities)

6.1 Day 1 – Dataset Collection and Literature Study

The internship began with the collection of relevant datasets related to UAV operations and
applications, especially focusing on fire and smoke detection, which is one of the critical real-
world applications of UAVs. I explored publicly available datasets and research archives that
contained annotated images and sensor data. This data was later used for understanding AI-based
detection systems in drones. Alongside, I reviewed academic literature to build a strong foundation
about UAV structures, applications in disaster management, and the role of datasets in AI-powered
detection. This day set the groundwork for both theoretical and practical aspects of the internship.

6.2 Day 2 – Airfoil Selection and VTOL UAV Concept Study

On the second day, I studied various research papers to understand airfoil selection, especially
focusing on fast airfoils suitable for fixed-wing UAVs. Special attention was given to the NACA
series of airfoils and their aerodynamic performance in UAV applications. This study directly
supported the development of a VTOL (Vertical Take-Off and Landing) fixed-wing UAV. By
comparing lift, drag, and efficiency parameters, I could better understand why certain airfoils are
preferred in UAV design.

6.3 Day 3 – Soldering Practice and Electronic Assembly (VTOL UAV)

This day focused on hands-on skills. I was trained in soldering techniques, which are crucial
for connecting electronic components like ESCs, sensors, and flight controllers in UAVs. Practical
exposure was gained by assembling parts of the VTOL fixed-wing UAV. This exercise not only
improved my technical skills but also taught me the importance of precision in electrical
connections, since poor soldering can cause signal losses and short circuits in drones.

19
6.4 Day 4 – Aerodynamic Calculations (Lift, Drag, Thrust)

The fourth day involved detailed aerodynamic calculations of lift, drag, and thrust for the
selected airfoils, particularly NACA0012 and MH60. Using aerodynamic equations and theoretical
tools, I calculated the coefficients of lift and drag. These calculations were essential to estimate
the performance of the UAV and predict its flight stability. I also compared the aerodynamic
efficiency of both airfoils under different Reynolds number conditions. This exercise gave me a
deeper understanding of the relationship between airfoil design and UAV performance.

6.5 Day 5 – Wiring and ESC Integration

On this day, I connected the servomotors of the VTOL UAV and performed wiring of the ESCs
(Electronic Speed Controllers) with the flight controller. This involved practical soldering,
placement of components, and testing continuity with multimeters. It was emphasized that neat
wiring is critical for UAV performance and safety. By the end of the day, I was confident in
connecting and testing small-scale electronic systems in UAVs.

6.6 Day 6 – Frame Construction of Flying Wing

The sixth day was focused on mechanical construction. I participated in building the frames of
the flying wing UAV. This involved cutting, assembling, and joining lightweight materials while
maintaining structural integrity and aerodynamics. The importance of weight distribution and
balance was explained, since even minor asymmetry can affect flight performance. This provided
an insight into structural design practices in aerospace engineering.

6.7 Day 7 – FPV Drone Study and SolidWorks Training

This day was divided between theoretical learning and software training. I was introduced to
FPV (First Person View) drone concepts, including the setup of cameras, transmitters, and VR
goggles for live flight operations. Additionally, I was trained in SolidWorks CAD software,
where I practiced 3D modeling of simple UAV components. SolidWorks training included
sketching, extrusion, part modeling, and assembly basics.

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6.8 Day 8 – UAV Part Design in SolidWorks

Building on the previous day, I modeled multiple UAV parts in SolidWorks, such as wing ribs,
fuselage structures, and propeller mounts. These parts were later assembled to create a preliminary
flying wing structure. This session gave me hands-on experience in translating engineering
drawings into 3D CAD models, an essential skill for aerospace engineers.

6.9 Day 9 – Composite Process and Control Panel Integration

The ninth day was focused on learning about composite materials in UAVs. I observed and
practiced basic composite lamination processes for UAV parts, which are widely used for
lightweight yet strong structures. After this, I worked on connecting the control panel to the flying
wing, integrating flight controllers and power distribution boards.

6.10 Day 10 – Assembly and Initial Flight Testing

On this day, the flying wing UAV underwent basic assembly. All structural parts were joined,
and electronic components were mounted. A ground test was performed to ensure all systems were
functioning properly. Following this, the UAV underwent its first low-altitude test flight, where
stability, lift, and thrust were monitored. This was significant milestone as it gave me exposure to
real UAV testing procedures.

6.11 Day 11 – Small Aircraft Modeling and 3D Printing Practice

I designed a small aircraft model in SolidWorks and exported it for 3D printing. This activity
taught me how CAD models can be directly translated into real components using additive
manufacturing. The hands-on 3D printing experience enhanced my understanding of prototyping
in aerospace engineering.

6.12 Day 12 – GPS Module and Advanced Wiring

On the twelfth day, I worked on precise wiring connections for the onboard GPS module and other

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electronic subsystems. This required careful soldering and integration with the main flight
controller. I learned how GPS improves UAV navigation and how it integrates with autonomous
flight systems.

6.13 Day 13 – Structural Assembly and System Integration

This day involved finalizing the painting and structural assembly of the UAV. The electronic
systems (ESCs, servos, GPS, flight controller, and sensors) were fully integrated. A functional test
was performed to verify communication between all subsystems. This was the stage where the
UAV transformed from parts into a complete, functional flying wing model.

6.14 Day 14 – Drone Technology Lecture and Pilot License Awareness

On the final day, a lecture session was held on drone technology, covering different UAV types,
their applications in industries, and working principles. Additionally, I was made aware of the
legal aspects of UAV flying, particularly DGCA regulations in India and the process of obtaining
a Remote Pilot License. This gave me industry-level knowledge beyond just technical skills.

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 CHAPTER 7
LEARNING OUTCOMES

The internship at Aakash Aerospace provided comprehensive exposure to UAV technologies,

aerospace design practices, electronics integration, and professional engineering methodologies.
The learning outcomes achieved through this program can be categorized into technical skills,
practical exposure, professional development, and industry awareness.

7.1 Technical Skills

The internship enhanced my technical proficiency in multiple domains of UAV development:

 UAV Aerodynamics and Airfoil Analysis

o Performed lift, drag, and thrust calculations for various NACA airfoils (e.g.,
NACA0012, MH60).
o Analyzed stability, control surfaces, and angle of attack for optimal UAV
performance.
o Understood the principles of low Reynolds number aerodynamics and its
implications on UAV design.
 CAD Modeling and 3D Design
o Created detailed 3D models of UAV components using SolidWorks.
o Assembled complete UAV structures digitally, ensuring proper fitment and
functionality.
o Generated engineering drawings with accurate dimensions and tolerances suitable
for manufacturing and 3D printing.
 Electronics and Systems Integration
o Practiced soldering, wiring, and calibration of ESCs, servomotors, and flight
controllers.
o Integrated GPS modules, ensuring proper signal reception and navigation support.

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 o Configured power distribution systems and battery management for safe UAV
operations.
 Composite Material Processing
o Learned lamination, curing, and finishing techniques for carbon fiber and fiberglass
components.
o Fabricated lightweight, structurally strong UAV parts.
o Conducted preliminary strength testing and quality checks of composite structures.
 3D Printing and Prototyping
o Prepared CAD models for additive manufacturing and learned slicing techniques.
o Fabricated functional UAV components, validating dimensional accuracy and
structural integrity.
o Applied iterative design improvements based on prototype testing.

7.2 Practical Exposure

The internship provided real-world exposure to UAV assembly, testing, and operations:

 UAV Structural Assembly

o Assembled flying wing and VTOL UAVs, ensuring proper alignment and weight
distribution.
o Integrated mechanical and electronic components to create functional UAV
systems.
 Flight Testing
o Conducted low-altitude test flights to observe UAV stability, responsiveness, and
control.
o Recorded flight parameters, compared them with theoretical predictions, and
identified areas for improvement.
 Project-Based Learning
o Followed a systematic workflow from design, fabrication, and integration to
testing.

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 o Gained experience in troubleshooting design and assembly issues during UAV
development.

7.3 Professional Skills

The internship also contributed to significant professional development

 Teamwork and Collaboration

o Worked closely with mentors, engineers, and peers to complete assembly and
testing tasks.
o Participated in group discussions, brainstorming sessions, and problem-solving
exercises.
 Technical Documentation and Reporting
o Maintained daily activity logs and progress reports.
o Learned to document UAV design procedures, testing results, and assembly
instructions effectively.
 Communication and Presentation Skills
o Presented project updates to mentors.
o Explained technical concepts and design decisions clearly and concisely.
 Time Management and Discipline
o Managed daily tasks efficiently to meet project deadlines.
o Learned to balance multiple aspects of UAV development simultaneously.

7.4 Industry Awareness

Through this internship, I gained insights into the professional aerospace environment

 Regulatory Knowledge
o Learned about DGCA UAV guidelines, pilot license requirements, and safety
protocols.
 Emerging UAV Technologies
o Understood current trends in VTOL, flying wing, autonomous UAVs, and AI
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 integration for surveillance and disaster management.

 Industry Standards and Best Practices

o Observed professional practices in UAV design, electronics integration, and quality
assurance.
o Learned the importance of precision, reliability, and compliance in aerospace
projects.

7.5 Personal Development

The internship also contributed to my personal growth

 Problem-Solving and Critical Thinking

o Learned to analyze design challenges and implement practical solutions during
assembly and testing.
 Adaptability and Learning Agility
o Adapted quickly to new software tools, technologies, and fabrication techniques.
 Confidence and Professional Attitude
o Gained confidence in working with complex UAV systems.
o Developed a professional approach to engineering tasks and project management.

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 CHAPTER 8
CONCLUSION

The internship at Aakash Aerospace has been an extremely enriching and transformative
experience, offering extensive exposure to the aerospace and UAV (Unmanned Aerial Vehicle)
industry. Over the course of the two-week program, I had the opportunity to bridge the gap between
theoretical knowledge gained during my academic studies and its practical application in a
professional engineering environment.

Key Learnings and Achievements

1. Technical Knowledge and Skills

o Gained hands-on experience in UAV design, including airframe structures, flying

wing and VTOL configurations.
o Developed proficiency in CAD modeling using SolidWorks, creating detailed UAV
components, assemblies, and engineering drawings.
o Acquired expertise in aerodynamic calculations, analyzing lift, drag, thrust, and
stability for optimal UAV performance.
o Learned electronics integration, including soldering, wiring, ESC calibration,
servomotor installation, GPS module integration, and battery management.
o Worked with composite materials, performing lamination, curing, and finishing of
lightweight yet strong UAV components.

2. Practical Exposure:
o Participated in UAV assembly, ensuring proper alignment, balance, and structural
integrity.
o Conducted ground tests and flight trials, evaluating UAV performance, stability,
and control characteristics.
o Applied theoretical knowledge to real-world problems, troubleshooting design,
electronics, and structural issues during the UAV development process.
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 3. Professional Development
o Enhanced teamwork and collaboration skills by working closely with mentors,
engineers, and fellow interns.
o Developed technical documentation, reporting, and presentation skills for
maintaining daily logs and conveying design progress.
o Learned time management, discipline, and professional ethics, essential for
industrial and engineering environments.
4. Industry Awareness and Insights:
o Gained understanding of DGCA UAV regulations, pilot licensing procedures, and
safety protocols.
o Observed professional practices in UAV design, testing, and quality assurance.
o Learned about emerging technologies in UAVs, including AI-based applications,
autonomous navigation, and hybrid VTOL systems.

Overall Impact

This internship has provided a holistic understanding of UAV development, combining

multiple domains such as aerodynamics, mechanical design, electronics, materials science, and
prototyping. It has enhanced my technical, analytical, and problem-solving skills, while also
improving my professional communication and project management abilities.

Future Implications

The exposure gained through this program has motivated me to:

 Pursue further research and specialization in aerospace engineering and UAV technologies.
 Explore AI integration and autonomous systems for UAV applications in disaster
management, surveillance, and logistics.
 Contribute to the development of innovative UAV prototypes with improved efficiency,
payload capacity, and autonomous capabilities.
 Stay updated with emerging trends in aerospace materials, additive manufacturing, and
UAV regulations for professional growth
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 CHAPTER 9
FUTURE SCOPE

The knowledge and skills gained during the internship open up several avenues for further
development and research in the field of UAVs and aerospace engineering:

1. Advanced UAV Design:

o Explore autonomous UAV swarms for industrial, military, and disaster
management applications.
o Design UAVs with enhanced payload capacity and energy-efficient propulsion
systems.
2. AI and Machine Learning Integration:
o Implement AI-powered vision systems for object detection, fire monitoring, search-
and-rescue operations, and real-time decision-making.
o Optimize flight paths and energy usage using machine learning algorithms.
3. VTOL and Hybrid UAV Systems
o Develop hybrid VTOL UAVs capable of both vertical take-off and efficient
forward flight.
o Research and improve transition mechanisms between rotary-wing and fixed-wing
flight modes.
4. Materials and Manufacturing Innovations
o Explore advanced composite materials and additive manufacturing for lightweight,
high-strength UAV structures.
o Implement multi-material 3D printing to integrate structural, electronic, and
aerodynamic functions in single components.
5. UAV Applications Expansion
o Design UAVs for medical supply delivery in remote areas and disaster zones.
o Develop UAV platforms for agriculture monitoring, environmental surveillance,
and industrial inspections.

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6. Regulatory and Safety Considerations
o Conduct research on UAV airspace management, safety protocols, and compliance
with national and international aviation standards.
o Develop UAV systems with fail-safe mechanisms and robust reliability for
autonomous operations.
7. Research and Higher Studies Opportunities
o The internship lays a strong foundation for pursuing higher studies in aerospace
engineering, UAV design, or robotics.
o Encourages exploration of innovative UAV prototypes and participation in
competitions or industrial R&D projects.

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 REFERENCES

1. Anderson, J.D., Fundamentals of Aerodynamics, 6th Edition, McGraw Hill, 2017.

2. Raymer, D.P., Aircraft Design: A Conceptual Approach, 6th Edition, AIAA, 2018.
3. DGCA, UAV Guidelines and Regulations, Directorate General of Civil Aviation, 2025.
4. Research Papers on UAV Airfoils and VTOL Designs:
o “Fixed-Wing UAV Design: A Systems Engineering Approach”, Research Gate,
2024.
o “Development of VTOL UAV and Strength Testing of Components”, AIP
Conference Proceedings, 2024.
o “3D Printed UAV Wings for Lightweight and Load Distribution Optimization”,
Research Gate, 2019.
5. SolidWorks Training Manuals and Tutorials, Dassault Systèmes, 2024.
6. Bambu Studio 3D Printing Documentation, 2024.
7. ArXiv and MDPI Journals on UAV Aerodynamics and Simulation Studies.
8. PMC Articles on 3D Printed Composite Materials for Aerospace Applications.

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APPENDICES

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