A Modular 3D-Printed Ducted-Fan Platform for Advanced Autonomy Research: From Design to Flight Test

Following the growing interest in small-scale unmanned aerial vehicles (UAVs), this paper presents a comprehensive conceptual design methodology for a modular ducted-fan aerial vehicle intended for research applications. Although ducted-fan configurations offer significant advantages over conventional multirotor platforms, particularly in urban, indoor, and human-interaction scenarios, the availability of affordable and customizable ducted-fan UAVs platforms suitable for scientific research remains limited. To address this gap, the paper details the complete design of the vehicle, including propeller aerodynamics and duct design, mechanical structure, actuation system, dynamic modeling, and control strategy. All major structural and aerodynamic components are fabricated using low-cost additive manufacturing, enabling rapid prototyping and high modularity. The vehicle’s performance is experimentally assessed through bench tests and indoor flight experiments, demonstrating stable flight and satisfactory attitude control. The presented work shows that a fully functional ducted-fan UAVs can be realized using commercial off-the-shelf electronics and exclusively 3D-printed components, and provides practical guidelines to replicate and adapt the proposed platform for advanced research in UAVs control, navigation, and autonomy.