Capstone/Senior Design

Overview - CyPayS

This project is part of a two-semester senior capstone sequence in aerospace engineering at Iowa State University. It spans AERE 4610 – Modern Design Methodology with Aerospace Applications (Spring 2025, Section 1 – Aircraft Focus, three credits) and AERE 4620 – Aerospace Systems Integration and Testing (Fall 2025, 3 credits).

Our team, Cyclone Payload Systems (CyPayS), consists entirely of aerospace engineering students randomly assigned to work together. While being a single-discipline team offers the benefit of a shared technical foundation, it has also presented unique challenges. Without the diverse expertise in multidisciplinary teams, we’ve often had to take on roles outside our core focus, such as structural analysis, control systems, and systems integration. These challenges have pushed us to adapt quickly, broaden our skill sets, and collaborate effectively to meet deadlines and deliver a complete, mission-ready product.

We were awarded a simulated contract to develop a fixed-wing small unmanned aerial system (sUAS) in response to a mock Department of Defense (DoD) Request for Proposal. The sUAS was required to carry a modular payload (5” × 2” × 3”, up to 1.5 lbs.), support hot-swappable and in-flight drop-capable payloads, and integrate a gimbal-mounted Teledyne FLIR Hadron640R RGB/thermal camera. Our system had to satisfy strict weight, size, cost, and mission performance requirements.

During AERE 4610, we focused on concept development, subsystem trade studies, CAD modeling, and performance analysis. This phase culminated in a well-justified preliminary design that met mission requirements while balancing manufacturability and integration across subsystems.

In AERE 4620 (Fall 2025), we will transition to the prototyping and testing phase, validating our design through iterative builds and flight testing between August and December 2025.

This page documents our design process, technical decisions, and the evolution of our sUAS system across both semesters, highlighting key contributions, challenges, and lessons learned.

The Problem & Request

Small unmanned aerial systems (sUAS) have continually been found to be useful for both the military and commercial sectors. Unfortunately, it seems that for every type of mission or payload, a new sUAS has to be developed. A group of key payload suppliers in the sUAV marketplace have identified that many small payloads could be built to meet within a volume of 5” x 2” x 3” with a payload weight varying from zero to one and a half pounds.

In order to kick start the development of a sUAS capable of carrying this modular payload, the DoD (Department of Defense) has issued an RFP (request for proposal) to small businesses nationwide. The RFP is for a fixed-wing sUAS capable of carrying the variable weight payload (0 to 1.5 lb) for at least 30 minutes. The main payload is to have hot-swap and in-flight dropping capabilities. The RFP also requires the sUAS to carry an RGB/thermal camera with a specified FOV and gimble range.

Key Customer Requirements

The table to the left outlines the core requirements provided in the RFP for our senior design project. These constraints defined the performance expectations for our modular sUAS, including flight time, payload capacity, size limitations, and system functionality.

Each value had a threshold (minimum required) and an objective (ideal target). Meeting the threshold was essential for compliance, while approaching or exceeding the objective added value to the design and increased the likelihood of selection.

Requirements such as in-flight payload drop, hot-swapping within 30 seconds, and gimbaled camera control significantly shaped our airframe layout, internal systems, and component selection. Balancing these constraints within the weight and budget limits was a central focus of our design process.

Roles and Organization

Below is an early organizational chart our team (Cyclone Payload Systems or CyPayS) created during the first week of the project. While responsibilities naturally evolved as the design progressed, this structure helped us divide work efficiently, stay aligned across subsystems, and focus on our individual strengths.

I primarily served as the Project Manager, responsible for keeping the team organized, tracking milestones, coordinating between subsystems, and supporting our documentation and presentations. In addition to managing the overall workflow, I also contributed directly to both our CAD and propulsion teams, helping with modeling tasks, and propulsion trade studies, and also helped guide decision-making.

Our group was composed entirely of aerospace engineering students, which made for smooth communication and strong technical collaboration. However, it also meant that each of us had to stretch into multiple roles—covering everything from structures and aerodynamics to avionics and systems integration.

A big shoutout to the team for their effort, flexibility, and commitment throughout the project. This organizational structure gave us a strong foundation from early concept selection through the final design review.

Here is a rough org chart the team made during the first week. This chart helped us diversify our workload and stay to our strengths.

Initial Concept 1

This design features a compact fuselage paired with a high-mounted wing and twin engines. The configuration was chosen to minimize the overall dimensions of the aircraft while still maintaining sufficient payload capacity and aerodynamic performance. Its streamlined fuselage and reduced footprint were aimed at enhancing cruise efficiency by minimizing aerodynamic drag.

Initial Concept 2

This concept uses a larger, rectangular fuselage with a mid-mounted wing and twin engines. It prioritizes payload capacity and ease of construction, offering generous internal volume for mission equipment. However, the increased fuselage surface area introduces a tradeoff—higher aerodynamic drag and reduced overall efficiency.

Initial Concept 3

This configuration features a high-mounted wing, twin-boom tail, and a centrally located pusher motor. It provides ample space for payload integration while isolating propulsion noise from the camera system, which may improve imaging quality. The twin-boom design enhances structural stability and allows for a modular, accessible fuselage—but also introduces complexity in boom design and integration.

Rough Final Concept View 1

Rough Final Concept View 2

Rough Final Concept View 3

Next Steps

To advance toward a mission capable prototype, CyPayS will begin the fall semester by finalizing a detailed manufacturing plan and completing the Design Sign Off Report. Early priorities include conducting stability analyses, specifically lateral and dynamic stability, to validate the sizing and effectiveness of control surfaces. The team will also investigate the aerodynamic impacts of the recently adopted blunt nose design (see image to the left), which was chosen to simplify gimbal integration. In parallel, further testing will be performed on the selected Cobra 4010/20 motor, with potential wind tunnel validation to ensure performance expectations are met. These efforts will inform key design refinements before fabrication begins.

Full Conceptual Design Report - Semester 1

Obviously, I couldn’t include every detail of our work from the first semester on this page. If you’re interested in a more in-depth look at our design process, trade studies, and technical justifications, feel free to view our full Conceptual Design Report. This 30-page document, written entirely in LaTeX, outlines our team’s work throughout the semester and provides a comprehensive look at how we arrived at our final design.

CyPayS_4610_Conceptual_Design_Report (3).pdf

Download CDR

© Iowa State University / Cyclone Payload Systems. All rights reserved.This project was created by students at Iowa State University as part of the Aerospace Engineering senior capstone. All content is for academic use only and may not be reused or republished without permission from the team or university.

Page updated

Google Sites

Report abuse