What was accomplished

The mechanical department completed a major structural redesign of the upper deck — the avionics and flight controller compartment. Unlike a conventional open framework relying on standoffs for spacing, this year's upper deck is a fully enclosed compartment, using solid carbon fiber side walls that box in and protect the internal electronics from debris, vibration, and airflow disturbance. The top plate features strategic geometric cutouts — a combination of X-shapes and triangular reliefs — to reduce overall weight while still allowing clean routing paths for internal wiring. The enclosure was also designed to securely house the GPS mast on top and mount the telemetry antennas directly onto the solid side walls.

With the enclosure geometry finalized, the department also completed the digital assembly of the arm-to-chassis interface, confirming that all four motor arms (M1–M4) integrate cleanly into the new enclosed structure via the dual-clamp mounting system.

Challenges and solutions

The primary challenge this week was balancing the benefits of a fully enclosed design against the added weight of solid structural walls, compared to a traditional open standoff arrangement. Solid walls provide superior protection for the sensitive avionics and flight controller inside, shielding them from wind, debris, and vibration exposure that an open frame would allow. To offset the added weight, the team introduced the X-shape and triangular cutouts into the top plate — removing material from areas of lower structural stress while preserving the wall's overall rigidity and protective function.

A further challenge was determining where to mount the GPS mast and telemetry antennas without interfering with the compartment's electronics or compromising signal quality. The team resolved this by integrating the GPS mast into the top plate directly and mounting the telemetry antennas onto the solid side walls, positioning them away from internal wiring to minimize signal interference.

Next Steps Plan

With the upper deck fully defined and structurally secure, the department will move on to designing the lower deck, focusing on a robust housing and secure mounting configuration for the battery payloads to establish a stable center of gravity.