Variable-Pitch Propellers For More Efficient Quadcopter

April 8, 2026 by Tyler August 19 Comments

Quadcopters tend to have very poor efficency because of their high disk loading. High disk loading– that is, how much weight each square meter of area swept by the propellers must carry–is almost unavoidable with conventinal quadcopters, which are controlled by throttling the four props. Make the propellers too big, and their inertia slows down that control loop, leading to stability problems. [rctestflight] had an idea to solve this, by borrowing a technology from the world of fixed-wing aviation: variable-pitch propellers.

In aircraft use, they are not new, dating back to the end of the first world war. They’re made for everything from the largest turboprops to the 75 kW(100 HP) Rotax 912. By varying the propeller pitch, you can keep the engine turning in its ideal RPM range but still vary thrust by taking a larger or shallower ‘bite’ out of the air with each sweep of the prop. You can probably see how this applies to the quadcopter: a well-designed pitch-change mechanism is going to be much quicker than throttling a big prop with lots of rotational inertia. That’s the theory.

To test it, [rctestflight] builds some large 3D-printed variable pitch props, hooks them up to regular drone motors via a belt drive, before going on–you guessed it–an RC test flight. To make that work, he’s got the pitch servo being driven from what should be the flight controller’s thrust output to each motor. Aside from the vibrations from imperfect balance on the 3D-printed props, it flies quite well– and much better with pitch control than trying to vary the RPMs of those heavy props. He’s even able to reverse the propeller pitch, making this perhaps the first quadcopter capable of autorotation. Well, almost, given that it lost control and came apart when he cut the throttle.

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Creating The World’s Most Efficient Quadcopter Drone

February 18, 2026 by Maya Posch 12 Comments

Keeping an eye on remaining battery charge. (credit: Luke Maximo Bell, YouTube)

Although not a typical focus of people who fly quadcopter drones for a hobby or living, endurance flying has a certain appeal to it for the challenge it offers. Thus, as part of his efforts to collect all the world records pertaining to quadcopter drones, [Luke Maximo Bell] has been working on a design that would allow him to beat the record set by SiFly Aviation at 3 hours and 11 minutes.

By using knowledge gained from his PV solar-powered quadcopter, [Luke] set about to take it all a few steps further. The goal was to get as much performance out of a single Watt, which requires careful balancing of weight, power output and many other parameters.

Crucial is that power usage goes up drastically when you increase the RPM of the propellers, ergo massive 40″ propellers were picked to minimize the required RPM to achieve sufficient lift, necessitating a very large, but lightweight frame.

The battery packs are another major factor since they make up so much of the weight. By picking high-density Tattu batteries and stripping these down even more this was optimized for as well, before even the wire gauge of the power wires running to the motors were investigated to not waste a single Watt or gram.

All of this seems to have paid off, as a first serious test flight resulted in a 3 hour, 31 minutes result, making it quite feasible that [Luke] will succeed with his upcoming attempt at the world’s longest flying electric multirotor record. Another ace up his sleeve here is that of forward movement as well as wind provides effectively free lift, massively reducing power usage and possibly putting the 4 hour endurance score within easy reach.

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Beating The World Record For Fastest Flying Drone Once Again

January 18, 2026 by Maya Posch 21 Comments

The fun part about world records is that anyone can take a swing at breaking them, which is what [Luke Maximo Bell] has been doing with the drone speed record for the past years, along with other teams in a friendly competition. After having some Aussie blokes previously smash the record with a blistering 626 km/h, the challenge was on for [Luke] and his dad to reclaim the title. This they did with the V4 of their quadcopter design, adding a range of improvements including new engines, new props and an optimized body to eek out more performance.

In the video we see these changes and the tests in detail. Interestingly, the simulations ran on the computer showed that the new body actually had to be larger, necessitating the use of a larger FDM printer. Fortunately a certain FDM 3D printer company sponsors just about everyone out there, hence the new design was printed on a Bambu Lab H2D, also making use of the dual extruder feature to print combined PETG/TPU parts.

It was also attempted to have a follow camera attached to a second FPV done in the form of a 360 degrees camera, but this turned out to be a bit too complex to get good shots, so this will have to be retried again.

In the end a new world record was set at an average of 657 km/h, which sets the stage for the next team to try and overtake it again. As for where the limit is, propeller airplanes have hit over 800 km/h, so there’s still quite a way to go before details like the sound barrier become a problem.

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EVTOL For Everyone

November 15, 2025 by Tyler August 14 Comments

While most of the world’s venture capital is off chasing anything with “AI” in the name in what many think looks increasingly like an inflated spherical film of soap molecules, in aviation all the hot money is betting on eVTOL: electric vertical take off and landing.

What if you want to get in on the eVTOL game but don’t have (or want) billionaire backing? Long-time contributor [spiritplumber] demonstrates how to do it on the cheap, with a low-cost quadcopter and a foam wing called Lift5.

Most eVTOL isn’t just quadcopters, after all — multirotors are great for playing with in the back yard, but their thrust-based lift makes for short range, and the engine-out options are all bad. Add a wing, and you can get that sweet, sweet dynamic lift. Add an extra, forward facing motor, and you can get thrust in the direction you need it most. That’s what [spiritplumber] is doing here: strapping a foam wing to a cheap quadcopter. Specifically, his custom frame for an Eiele F120 drone kit.You can see it in action in the demo video embedded below.

The wing and its forward thrust motor are equipped with its own speed controller, so the concept should be adaptable to just about any little drone. Quadcopter flight computers are mostly going to be able to compensate for the added lift and thrust automatically, which is neat, considering that these forces would require some bizarre headwind/updraft very unlikely to be found in nature.

Now the wing does add a lot of drag during the lift phase, to be sure, so [spiritplumber] is working on folding or tilting it out of the way, but that version is apparently inordinately fond of trees. Once the control issues are worked out you’ll likely see it on his site and YouTube channel Robots Everywhere.

[spiritplumber] has been contributing hacks here at least since 2009, when he showed us how to make a Macbook right click.

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Building A PV Solar-Powered Quadcopter

November 1, 2025 by Maya Posch 71 Comments

The solar-powered quadcopter from below. (Credit: Luke Maximo Bell)

One of the most frustrating parts about flying a quadcopter is having to regularly swap battery packs, as this massively limits what you can do with said quadcopter, never mind its effective range. Obviously, having the sun power said quadcopter during a nice sunny day would be a much better experience, but how workable is this really? While airplanes have used solar power to stay aloft practically indefinitely, a quadcopter needs significantly more power, so is it even possible? Recently, [Luke Maximo Bell] set out to give it a whirl.

His quadcopter build uses a large but very lightweight carbon fiber frame, with large 18″ propellers. This provides the required space and lift for the solar panel array, which uses 27 razor-thin panels in a 9×3 grid configuration supported by a lightweight support frame.

Due to the lightweight construction, the resulting quadcopter actually managed to fly using just the direct power from the panels. It should be noted however that it is an exceedingly fragile design, to the point that [Luke]’s cat broke a panel in the array when walking over it while it was lying upside-down on a table.

After this proof of concept, [Luke] intends to add more panels, as well as a battery to provide some buffer and autonomous flying hardware, with the goal of challenging the world record for the longest flying drone. For the rest of us, this might make for a pretty cool idea for a LoRaWAN mesh node or similar, where altitude and endurance would make for a great combo.

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POV Globe Takes To The Skies

October 22, 2025 by Tyler August 14 Comments

LED billboards are cyberpunk-dystopian enough for most, but it can get worse. For example, this project by [Concept Crafted Creations] that takes the whole concept and takes it airborn (literally) in the form of a flying POV sphere called “Zippy”.

We love persistence-of-vision (POV) displays, and have featured plenty before, from the very complicated to the fairly simple. The idea is simple: take one or more rings of LEDs and spin them rapidly enough that the persistence-of-vision effect creates a solid image in your visual field. We covered the basics years back. “Zippy” has one ring of addressable LEDs that surrounds the thing that makes it unique: the quadcopter at its core. None of those other projects could fly, after all.

You might imagine a big, spinning ring is going to have a lot of torque to cancel out, and that is true — about 2.3 kgf — and it led to a lot of prototypes crashing early on. After trying to use flaps to direct the downwash of the quadcopter rotors to counter the spin, [Concept Crafted Creations] eventually added two extra props for yaw control, and that seemed to do the trick. We say “quadcopter” because that’s the configuration, but Zippy ended up heavy and needs eight lift motors to fly. PVC pipe and PLA aren’t the lightest build materials, after all. That’s ten props, total, plus another outrunner to spin the POV ring. All those motors, plus the current draw of the LEDs means the flight time might not impress — but Zippy sure does, at last as long as the batteries hold out.

There’s something eye-catching about POV displays, and seeing this one drifting upwards like Kang and Kodos decided to steal the Los Vegas Sphere is even more arresting. That made the crash at the end of the video sad to see, but [Concept Crafted Creations] hasn’t ruled out rebuilding it if his viewers show enough interest. So if you like what you see, head over to YouTube and leave an encouraging comment for him to try, try again. Continue reading “POV Globe Takes To The Skies” →

Making The Tiny Air65 Quadcopter Even Smaller

October 14, 2025 by Maya Posch 15 Comments

First person view (FPV) quadcopter drones have become increasingly more capable over the years, as well as much smaller. The popular 65 mm format, as measured from hub to hub, is often considered to be about the smallest you can make an FPV drone without making serious compromises. Which is exactly why [Hoarder Sam] decided to make a smaller version that can fit inside a Pringles can, based on the electronics used in the popular Air65 quadcopter from BetaFPV.

The 22 mm FPV drone with camera installed and looking all cute. (Credit: Hoarder Sam)

The basic concept for this design is actually based on an older compact FPV drone design called the ‘bone drone’, so called for having two overlapping propellers on each end of the frame, thus creating a bone-like shape. The total hub-to-hub size of the converted Air65 drone ends up at a cool 22 mm, merely requiring a lot of fiddly assembly before the first test flights can commence. Which raises the question of just how cursed this design is when you actually try to fly with it.

Obviously the standard BetaFPV firmware wasn’t going to fly, so the next step was to modify many parameters using the Betaflight Configurator software, which unsurprisingly took a few tries. After this, the fully loaded drone with camera and battery pack, coming in at a whopping 25 grams, turns out to actually be very capable. Surprisingly, it flies not unlike an Air65 and has a similar flight time, losing only about 30 seconds of the typical three minutes.

With propellers sticking out at the top and bottom – with no propeller guards – it’s obviously a bit of a pain to launch and land. But considering what the donor Air65 went through to get to this stage, it’s honestly quite impressive that this extreme modification mostly seems to have altered its dimensions.

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