Reverse engineering and parametric CAD of a quadcopter UAV

Project · Project 6

The detailed reverse engineering and full CAD reconstruction of a commercial quadcopter, producing a complete digital twin composed of 98 individual components (41 unique parts) organised into 9 functional subassemblies, including propulsion, chassis, battery and control systems.

Method

The project involved precise dimensional measurement of the physical system and its translation into fully constrained parametric models. Engineering tolerances were held down to 0.005 mm and 1 degree for critical components, ensuring high geometric fidelity and assembly compatibility rather than a loose visual approximation.

Detailed technical drawings were generated for every component — gears, structural arms, propellers and electronic housings — and full-system integration was validated through hierarchical assembly modelling, capturing the mechanical interfaces, load paths and motion transmission from motors to propellers.

Real Eachine E58 alongside the CAD reconstruction/assets/img/projects/uav-real-vs-cad.png

Fig. 1 — Actual Eachine E58 and the reconstructed CAD model.

Exploded view of the full assembly/assets/img/projects/uav-exploded.png

Fig. 2 — Exploded view showing the 9 functional subassemblies.

Results

Beyond the geometry itself, the functional architecture of the UAV was analysed — power distribution, propulsion mechanics and structural layout — linking each design decision back to performance and operational constraints.

Rendered views of the completed digital twin/assets/img/projects/uav-render.png

Fig. 3 — Rendered and transparent views of the completed model.