UAV Design
Historical Development of UAVs,
Classification and Successful UAV’s
Mr. Nirmith Kumar Mishra
Assistant Professor
Department of Aeronautical Engineering
1.1 Introduction to UAVs
UAVs are remotely piloted or autonomous air vehicles carrying
payloads like cameras, sensors, and communication systems.
Terminology:
UAV (Unmanned Aerial Vehicle)
UAS (Unmanned Aerial System) – preferred by the Department of
Defense (DoD)
Drone – commonly used in media reports
Conduct critical missions without endangering personnel and at a
lower cost than manned aircraft.
1.1.1 UAV Design Process
UAV design follows principles of engineering design.
Design involves:
✓ Analytical processes
✓ Drafting and visualization
✓ Problem-solving techniques
Modern UAV designs require optimization and computational
analysis.
1.1.2 Evolution and Growth of UAVs
✓ Research on UAVs has expanded significantly over the past two
decades.
✓ Historically focused on endurance and range, modern UAVs cater
to diverse applications.
✓ Applications span both civilian (surveying, logistics, agriculture)
and military (reconnaissance, surveillance, combat) sectors.
1.1.2 Evolution and Growth of UAVs
Early performance assessments in UAV design include cost,
manufacturability, and operational effectiveness.
✓ UAVs like Predator and Global Hawk exemplify advancements in
UAV technology.
1.1.3 UAV Regulations
❖ FAA Regulations (2016): First operational rules for commercial
UAVs.
❖ FAR Part 107: Defines small UAVs (sUAS) as those < 55 lb (25
kg).
✓ Restrictions under Part 107:
✓ Max altitude: 400 ft
✓ AGL500 ft below clouds
✓ 3-mile visibility
1.1.4 UAV Design Challenges
❖ UAVs share design principles with manned aircraft but face
unique challenges:
i. Structural constraints (G-loads, pressurization)
ii. Integration of autopilot, ground stations, and communication
systems.
iii. Advances in autonomous systems and AI integration
❖ Use of multi-objective genetic algorithms in UAV optimization.
1.1.5 Technological Advances in UAV Design
❖ Early UAVs (1990s) were based on full-scale aircraft design
principles.
❖ Computing advancements have enabled detailed UAV
configuration analysis.
❖ UAVs must operate in controlled airspace with advanced
navigation and control systems.
1.1.6 UAV System Components
A UAV system consists of five major elements:
i. Environment – Includes airspace, data links, and relay UAVs.
ii. Air Vehicle Element – The UAV itself.
iii. Mission Control Element – Ground control stations.
iv. Payload Element – Cameras, sensors, and other equipment.
v. Support Element – Maintenance, logistics, and support systems
1.1.7 Global Adoption of UAVs
❖ Countries using UAVs for civilian and military applications
include USA, China, Israel, India, Russia, UK, France, Germany,
Turkey, and others.
❖ As of 2025, the utilization of Unmanned Aerial Vehicles (UAVs)
has expanded significantly across both military and commercial
sectors.
❖ In 2024, global commercial drone flight hours reached
approximately 10.8 million.
❖ General Atomics' Predator-series UAVs continue to dominate UAV
deployments worldwide.
1.1.8 Global Adoption of UAVs
❖ In October 2024, the Indian government finalized a $4 billion
agreement to acquire 31 MQ-9B Predator drones, aiming to
bolster surveillance and defense operations, particularly along its
borders.
❖ The integration of these advanced UAVs is poised to significantly
enhance India's intelligence, surveillance, and reconnaissance
(ISR) capabilities, contributing to national security and defense
modernization efforts.
1.1.9 Economic Impact and Future of UAVs
❖ UAVs are revolutionizing industries like energy, telecom,
construction, and agriculture.
❖ As of January 2025, the Directorate General of Civil Aviation
(DGCA) in India has been actively advancing the integration of
Unmanned Aerial Vehicles (UAVs) into civil airspace.
❖ In July 2024, the central government increased incentives for
drone manufacturing by 37.5%, allocating ₹165 crore over three
years to bolster the domestic drone industry.
1.1.9 Economic Impact and Future of UAVs
❖ The DGCA is also developing a comprehensive regulatory
framework for advanced air mobility solutions, including electric
Vertical Take Off and Landing (eVTOL) aircraft.
❖ This initiative aims to manage UAV operations strategically and
tactically by optimizing air traffic flow through Unmanned Aircraft
Traffic Management (UTM) systems, integrated with existing Air
Traffic Management (ATM) systems.
1.1.10 UAV Design Methodologies
❖ UAV design follows three major phases:
❖ Conceptual Design – Initial feasibility and performance
assessment.
❖ Preliminary Design – Structural, aerodynamic, and mission
analysis.
❖ Detailed Design – Full system integration and optimization.
1.2 Classification of UAVs
❖ Unmanned Aerial Vehicles (UAVs) have diverse applications in
military, commercial, and research fields.
❖ UAVs vary in terms of cost, size, weight, mission, and users.
1.2.1 Based on Weight:
i. Micro Air Vehicles (MAVs): Weigh less than one pound.
ii. Mini UAVs: Weigh between 1 to 25 kg.
iii. Small UAVs: Vary from 25 kg to 150 kg.
iv. Medium UAVs: Range from 150 kg to 600 kg.
v. Large UAVs: Weigh more than 600 kg.
1.2.2 Based on Mission
Reconnaissance & Surveillance: Monitoring enemy activity (e.g.,
Global Hawk).
Combat UAVs: Unmanned Combat Aerial Vehicles (UCAVs) used for
strike missions (e.g., X-45).
Electronic Warfare: UAVs used for disrupting enemy
communication.
1.2.2 Based on Mission
Communication Relay: Used in disaster response to enhance
network coverage.
Logistics: UAVs for supply delivery.
Research & Development: Used for atmospheric and environmental
studies (e.g., University of Kansas North Pole UAV).
1.2.3 Based on Tactical Role
Micro UAVs (MUAVs): Less than 15 cm in size, developed for
military operations by DARPA.
Tactical UAVs: Support tactical commanders with real-time
intelligence (e.g., Outrider, Hunter).
MALE UAVs: Medium-Altitude, Long-Endurance UAVs for
surveillance (e.g., Predator).
HALE UAVs: High-Altitude, Long-Endurance UAVs for long-range
operations (e.g., Global Hawk).
1.2.4 Based on Airspace Classification
Category G: Micro, mini, small UAVs, and quadcopters.
Category A: MALE UAVs.
Categories B, C, D, and E: Tactical UAVs.
Large UAVs require transponders to declare flight characteristics.
UAV Classification
Normal operating
No UAV Class Weight (lb) Size Range (km) Endurance
altitude
1 Micro < 0.55 < 10 cm < 100 ft 0.1-0.5 < 1 hr
2 Mini 0.55-2 10-30 cm < 500 ft 0.5-1 < 1 hr
3 Very small 2-5 30-50 cm < 1000 ft 1-5 1-3 hr
4 Small 5 - 55 0.5-2 m 1,000-5,000 ft 10-100 0.5-2 hr
5 Medium 55-1,000 5-10 m 10,000-15000 ft 500-2,000 3-10 hr
6 Large 10,000-30,000 20-50 m 20,000-40,000 ft 1,000-5,000 10-20 hr
Tactical/
7 1,000-20,000 10-30 m 10,000-30,000 ft 500-2,000 5-12 hr
combat
8 MALE 1000-10,000 15-40 m 15,000-30,000 ft 20,000-40,000 20-40 hr
9 HALE > 5,000 20-50 m 50,000-7,0000 ft 20,000-40,000 30-50 hr
20 min – 1
10 Quadcopter 0.5- 100 0.1 – 1 m < 500 ft 0.1 - 2
hr
13 mm – 10 min – 2
11 Helicopter 0.001 - 200 < 500 ft 0.2 - 5
2m hours
Table 1.1. UAV classification
Ref: Sadraey, Mohammad H. Design of Unmanned Aerial Systems. John
Wiley & Sons Ltd, 2020
UAV Classification as per DGCA
Fig 1.1. UAV Classification as per DGCA
Ref: https://digitalsky.dgca.gov.in/home
1.2.5 UAV Configurations
Fixed-Wing UAVs Rotary-Wing UAVs
Require a runway or launcher for Can take off and land vertically.
takeoff.
Used for high-speed, long-endurance Includes unmanned helicopters and
missions. quadcopters.
Example: Scan Eagle (small UAV), Example: Yamaha RMAX (unmanned
Predator (MALE UAV), Global Hawk helicopter with a max mass of 94 kg
(HALE UAV). and an endurance of one hour).
Table 1.2. UAV Configurations
1.3. Successful UAV’s
1.3.1.a Global Hawk (HALE UAV)
Manufacturer: Northrop Grumman
First Flight: 28 February 1998
Mission: Intelligence, surveillance, and reconnaissance (ISR).
Significance: First UAV to autonomously cross the Pacific
(Guinness Record).
Operates at high altitudes for long endurance.
1.3. Successful UAV’s
1.3.1.a Global Hawk (HALE UAV)
Specifications:
Wingspan: 39.9 m
Length: 14.5 m
Max Takeoff Weight (MTOW): 14,628 kg
Engine: Rolls Royce F137-RR-100 turbofan (34 kN thrust)
1.3. Successful UAV’s
…1.3. Successful UAV’s:
1.3.1.a Global Hawk (HALE UAV)
Performance: Max Speed: 340 knots
Cruise Speed: 310 knots
Range: 22,779 km
Endurance: 32+ hours
Service Ceiling: 60,000 ft Fig 1.2. Global Hawk
Ref: Sadraey, Mohammad H. Design of Unmanned
Aerial Systems. John Wiley & Sons Ltd, 2020
UAV Design
1.3. Successful UAV’s:
1.3.1.b RQ-170 Sentinel
Manufacturer: Lockheed Martin
Mission: Stealth reconnaissance UAV
Significance:
i. Used by the CIA.
ii. Operates at high altitudes with low visibility.
UAV Design
1.3. Successful UAV’s:
1.3.1.b RQ-170 Sentinel
Specifications:
Design: Tail-less stealth UAV
Operational Use: Intelligence gathering
Fig 1.3. Lockheed Martin RQ-170
Ref: Sadraey, Mohammad H. Design of Unmanned
Aerial Systems. John Wiley & Sons Ltd, 2020
Conclusion
❖ UAVs continue to evolve with advancements in AI, automation,
and aerodynamics.
❖ Design challenges involve balancing cost, payload capacity, range,
and mission objectives.
❖ Future UAV development will focus on autonomy, endurance, and
multi-role capabilities.
Conclusion
❖ UAVs have a broad range of classifications based on weight,
mission, airspace, and military application.
❖ They play a crucial role in military operations, commercial
applications, research, and disaster response.
❖ Future UAV developments focus on swarm technology, artificial
intelligence, and extended endurance capabilities.
References
[1]. Sadraey, Mohammad H. Design of Unmanned Aerial Systems. John Wiley & Sons
Ltd, 2020
[2]. Aerospace Industries Association (AIA). (2021). The Economic Impact of UAV
Integration into Civil Airspace. Retrieved from www.aia-aerospace.org
[3] Federal Aviation Administration (FAA). (2016). Small Unmanned Aircraft
Systems Regulations (Part 107). Retrieved from www.faa.gov
[4]. DARPA. (2022). Micro Air Vehicle (MAV) Programs. Retrieved from
https://www.darpa.mil
[5]. https://digitalsky.dgca.gov.in/home
