As an intern at Textron Systems in Hunt Valley MD, I worked for the Air Systems team on the MK 4.8 Hybrid Quad version of the Aerosonde, a small VTOL UAV (~200 lbs with a ~15 ft wingspan) designed to perform reconnaissance and collect data in various remote combat areas.

While I was there, the team was working on readying the MK 4.8 HQ for final release, which meant updating many prototype components carried over from previous generation UAVs as well as streamlining the manufacturing, assembly, and field maintenance processes for the air vehicle. As part of this process, I designed a size, weight, and CG representative flight testing analog for a new encryption module to be used with various payloads, including mounting provisions for appropriate connectors to test cable harnessing.

In addition, I designed and prototyped additional support structures to streamline the assembly and field maintenance procedures for the MK 4.8 HQ. Since the UAV is heavier and has a larger wingspan compared to its predecessors, an improved assembly jig was required to allow for the rapid installation and removal of the heavy booms which hold the electric motors and propellers. These wing supports were designed to be collapsed and stowed by a single operator to be easily deployed both at the plant or out in the field.