# Solution Draft (Rev 07) — Complete UAV BOM & Cost Analysis

Reconnaissance fixed-wing UAV. 18 kg MTOW, 3.8m wingspan, catapult launch, parachute recovery. S2 GFRP airframe with CF wing spar. Optimized for radio transparency, parachute landing durability, and field repairability.

## Material Architecture

**S2 fiberglass (GFRP) everywhere** — skins, fuselage structure, ribs, hat-section stiffeners, tail surfaces, control surfaces. **Carbon fiber only in the main wing spar** (one per wing half, carry-through at fuselage center section).

The CF wing spar runs spanwise through the wing and connects at the fuselage center section, providing flutter resistance and torsional rigidity. The fuselage remains 100% GFRP — fully RF-transparent, radar-transparent, field-repairable, with no hidden damage from parachute landings.

Fuselage panels use foam-core sandwich construction (S2 FG skins over PVC foam core). Hat-section S2 FG ribs at load-bearing stations.

## Bill of Materials — Complete UAV (Per Unit)

### 1. Composite Reinforcement Fabrics

| # | Component | Specification | Qty | Weight | Unit Price | Total | Link | Why This |
|---|-----------|---------------|-----|--------|-----------|-------|------|----------|
| 1.1 | S2-glass cloth, 6oz plain weave | Style 4533, 30" width, aerospace silane finish | 15 yd | ~2.0 kg (in laminate) | $10.45/yd | $156.75 | [LeapTech](https://www.carbonfiberglass.com/product/6oz-s-glass-27-width-html/) | S2 provides 30-40% higher tensile strength and 10× fatigue life vs E-glass. 6oz for 2mm skin layups (3-4 layers). Plain weave for compound curves. |
| 1.2 | S2-glass cloth, 9oz satin weave | Style 7781, 38" width | 5 yd | ~0.8 kg (in laminate) | $14.50/yd | $72.50 | [LeapTech](https://www.carbonfiberglass.com/product/8-9oz-s-glass-satin-weave-38-width-html/) | Satin weave drapes on tight-radius parts (nose cone, wing root fairing). 9oz for wing root junction reinforcement. |
| 1.3 | CF unidirectional tape, 250gsm, 50mm | 12K, glass cross-stitch | 8 m | ~0.15 kg | $4.70/m | $37.60 | [Easy Composites](https://www.easycomposites.co.uk/250g-unidirectional-carbon-fibre-tape) | Maximum stiffness along spar axis. 50mm matches spar cap. 4-6 layers per cap. |
| 1.4 | E-glass cloth, 4oz plain weave | Standard, 50" width | 3 yd | — | $4.50/yd | $13.50 | [The Gelcoater](https://www.thegelcoater.com/pages/6oz-200-gsm-plain-weave-e-glass) | Non-structural areas: cable guides, servo mount pads. E-glass adequate where S2 premium isn't needed. |

**Subtotal fabrics: ~$280 / ~3.0 kg in laminate**

### 2. Matrix Resin System

| # | Component | Specification | Qty | Weight | Unit Price | Total | Link | Why This |
|---|-----------|---------------|-----|--------|-----------|-------|------|----------|
| 2.1 | Aeropoxy PR2032 + PH3660 hardener | 3:1 mix, 1-hour pot life | 1 qt kit | ~0.9 kg | $81.50 | $81.50 | [Aircraft Spruce](https://www.aircraftspruce.com/catalog/pnpages/01-42135.php) | Aerospace-grade, Rutan-tested. Room-temp cure. Good wet-out. Compatible with S2 FG and CF. |
| 2.2 | Aeropoxy PR2032 + PH3630 fast hardener | 3:1 mix, 30-min pot life | 1 pint | ~0.45 kg | $45.00 | $45.00 | [Aircraft Spruce](https://www.aircraftspruce.com/catalog/cmpages/aeropoxy.php) | Fast hardener for bonding joints, fillets, quick repairs. |

**Subtotal resin: ~$127 / ~0.8 kg in structure**

### 3. Core Material

| # | Component | Specification | Qty | Weight | Unit Price | Total | Link | Why This |
|---|-----------|---------------|-----|--------|-----------|-------|------|----------|
| 3.1 | PVC foam core, 3mm, 80 kg/m³ | EasyCell 75 / Divinycell H80 | 8 sheets | ~0.33 kg | $9.10/sheet | $72.80 | [Easy Composites](https://www.easycomposites.us/easycell75-closed-cell-pvc-foam) | Fuselage panels, tail surfaces. 3mm foam + 2×1mm FG skins = ~5mm sandwich. |
| 3.2 | PVC foam core, 5mm, 80 kg/m³ | Same material, thicker | 4 sheets | ~0.27 kg | $9.10/sheet | $36.40 | [Easy Composites](https://www.easycomposites.us/easycell75-closed-cell-pvc-foam) | Wing trailing edge panels and control surfaces. |

**Subtotal core: ~$109 / ~0.60 kg**

### 4. Consumables (Layup & Cure)

| # | Component | Specification | Qty | Unit Price | Total | Link |
|---|-----------|---------------|-----|-----------|-------|------|
| 4.1 | Vacuum bagging kit | Film, sealant tape, peel ply, breather, tubing | 1 kit | $42.48 | $42.48 | [Fiberglass Supply](https://fiberglasssupply.com/basic-vacuum-bagging-kit/) |
| 4.2 | Mold release wax | Partall paste wax, 12oz | 1 can | $18.00 | $18.00 | [Aircraft Spruce](https://www.aircraftspruce.com) |
| 4.3 | PVA mold release | Liquid, 1 pint | 1 pint | $12.00 | $12.00 | [Aircraft Spruce](https://www.aircraftspruce.com) |
| 4.4 | Mixing cups, brushes, squeegees | Assorted laminating tools | 1 set | $25.00 | $25.00 | Various |
| 4.5 | Sandpaper assortment | 80, 120, 220, 400 grit | 1 pack | $15.00 | $15.00 | Various |
| 4.6 | Acetone / IPA | Surface cleaning, 1 gallon | 1 gal | $12.00 | $12.00 | Various |

**Subtotal consumables: ~$125**

### 5. Structural Hardware

| # | Component | Specification | Qty | Weight | Unit Price | Total | Link | Why This |
|---|-----------|---------------|-----|--------|-----------|-------|------|----------|
| 5.1 | Wing root aluminum fittings | 6061-T6, CNC machined | 2 pcs | ~120g | $35.00/pc | $70.00 | [SendCutSend](https://sendcutsend.com) | Transfers wing bending loads to fuselage. Small, inspectable, not in RF path. |
| 5.2 | Wing spar carry-through tube | Pultruded CF tube, 25mm OD × 1.5mm | 0.6 m | ~60g | $15.00 | $15.00 | [DragonPlate](https://dragonplate.com) | Connects L/R wing spars through fuselage. Airframe backbone. |
| 5.3 | Control surface hinges | Composite-compatible pin hinges, 50mm | 10 pcs | ~50g | $2.50/pc | $25.00 | [Aircraft Spruce](https://www.aircraftspruce.com) | Aileron (4), elevator (4), rudder (2). Stainless steel pins. |
| 5.4 | Servo mounting plates | G10 fiberglass, 3mm, 100×60mm | 5 pcs | ~45g | $3.00/pc | $15.00 | [Aircraft Spruce](https://www.aircraftspruce.com) | RF-transparent, strong, bonds into FG structure. |
| 5.5 | Threaded inserts | M3 and M4 brass | 30 pcs | ~30g | $0.50/pc | $15.00 | Various | Access panels, servo covers, wing mounting. |
| 5.6 | Stainless fasteners | M3, M4 bolts/nuts/washers kit | 1 kit | ~80g | $20.00 | $20.00 | Various | Corrosion resistant. |
| 5.7 | Push rods + clevis | 2mm steel rod + nylon clevis | 5 sets | ~60g | $4.00/set | $20.00 | [HobbyKing](https://hobbyking.com) | Servo-to-surface linkage. |

**Subtotal hardware: ~$180 / ~0.45 kg**

### 6. Belly Protection (Parachute Landing)

| # | Component | Specification | Qty | Weight | Unit Price | Total | Why This |
|---|-----------|---------------|-----|--------|-----------|-------|----------|
| 6.1 | Replaceable belly panel | S2 FG / foam sandwich, 2mm skins + 3mm foam | 2 pcs (1+spare) | ~150g each | $15.00/pc | $30.00 | Sacrificial panel, field-swappable in <10 min. |
| 6.2 | EVA foam bumper strip | 15mm closed-cell, adhesive-backed | 1 m | ~40g | $5.00 | $5.00 | Wraps gimbal cavity. Absorbs minor impacts. |

**Subtotal belly protection: ~$35 / ~0.19 kg installed**

### 7. Parachute Recovery System

| # | Component | Specification | Qty | Weight | Unit Price | Total | Link | Why This |
|---|-----------|---------------|-----|--------|-----------|-------|------|----------|
| 7.1 | Fruity Chutes FW Recovery Bundle | IFC-120-S Iris Ultra Compact + pilot chute + deployment bag + Y-harness + shock cord | 1 system | 950g | $830.00 | $830.00 | [Unmanned Systems Source](https://www.unmannedsystemssource.com/shop/parachutes/fixed-wing-bundles/fixed-wing-recovery-bundle-44lbs-20kg-15fps/) | Proven fixed-wing recovery system. IFC-120-S canopy rated 44lb (20kg) @ 15fps (4.6 m/s). Pilot chute ensures reliable air-stream deployment. Spectra shroud lines. Compact packing (190 cu"). Repackable. No pyrotechnics, no CO2 — just pilot chute + deployment bag for planned parachute landings. |
| 7.2 | Servo-actuated hatch | Spring-loaded door, triggered by autopilot | 1 | 80g | $30.00 | $30.00 | Custom | Autopilot triggers servo → spring ejects parachute bag into airstream. Same concept as Shark M: simple, reusable, no gases or explosives. |
| 7.3 | Parachute riser cutter | Servo-actuated line cutter | 1 | 30g | $40.00 | $40.00 | Custom | Cuts risers after touchdown to prevent wind drag. |

**Subtotal parachute: ~$900 / ~1.06 kg**

### 8. Propulsion

| # | Component | Specification | Qty | Weight | Unit Price | Total | Link | Why This |
|---|-----------|---------------|-----|--------|-----------|-------|------|----------|
| 8.1 | T-Motor AT4120 KV250 | Long shaft pusher motor, 12S rated, 2100W max | 1 | 304g | $110.00 | $110.00 | [T-Motor Store](https://store.tmotor.com/product/at4120-long-shaft-vtol-pusher-motor.html) | 12S rated, triple-bearing long shaft for pusher config. At 40-50% throttle: 275W cruise, 7.8-8.7 g/W efficiency. 304g is lightweight for this power class. |
| 8.2 | T-Motor ALPHA 60A 12S ESC | FOC, 18-50.4V, 60A continuous | 1 | 73g | $110.00 | $110.00 | [T-Motor Store](https://store.tmotor.com/product/alpha-60a-12s-esc.html) | Matched to AT4120 motor. FOC for smooth low-RPM cruise. 60A continuous gives ample margin over ~7A cruise draw. Built-in protections. |
| 8.3 | APC 16×8E propeller | Thin electric, fiberglass nylon | 3 pcs (1+2 spare) | ~52g each | $10.00/pc | $30.00 | [APC Propellers](https://www.apcprop.com/product/16x8e/) | Excellent efficiency data matched with AT4120. 16" diameter for high propulsive efficiency at low RPM. Spares included — props are consumables. |

**Subtotal propulsion: ~$250 / ~0.43 kg installed**

### 9. Servos

| # | Component | Specification | Qty | Weight | Unit Price | Total | Link | Why This |
|---|-----------|---------------|-----|--------|-----------|-------|------|----------|
| 9.1 | Digital metal gear servos | HV, 5-10 kg·cm torque, coreless | 5 pcs | ~175g total | $25.00/pc | $125.00 | [Savox](https://www.savox.com) / [KST](https://kstservos.com) | 2 aileron, 2 elevator, 1 rudder. Metal gears for reliability. HV (6-8.4V) powered direct from BEC. Coreless for precision and longevity. |

**Subtotal servos: ~$125 / ~0.18 kg**

### 10. Flight Controller & Navigation

| # | Component | Specification | Qty | Weight | Unit Price | Total | Link | Why This |
|---|-----------|---------------|-----|--------|-----------|-------|------|----------|
| 10.1 | Holybro Pixhawk 6X Mini Set | STM32H753, triple IMU, PM02D power module | 1 set | ~38g | $313.00 | $313.00 | [Holybro](https://holybro.com/products/pixhawk-6x) | Industry standard for ArduPilot. Triple redundant IMU. Ethernet for Jetson link. Mini form factor for fixed-wing. |
| 10.2 | Holybro M10 GPS | u-blox M10, GPS/Galileo/GLONASS/BeiDou, compass | 1 | ~20g | $44.00 | $44.00 | [Holybro](https://holybro.com/collections/gps/products/m10-gps) | Matches Pixhawk 6X connector. Multi-constellation GNSS. Includes IST8310 compass, buzzer, safety switch. |

**Subtotal flight controller: ~$357 / ~0.06 kg**

### 11. Onboard Computer

| # | Component | Specification | Qty | Weight | Unit Price | Total | Link | Why This |
|---|-----------|---------------|-----|--------|-----------|-------|------|----------|
| 11.1 | NVIDIA Jetson Orin Nano Super 8GB | 67 TOPS AI, ARM Cortex-A78AE | 1 | ~60g (board only) | $249.00 | $249.00 | [NVIDIA](https://www.nvidia.com/en-us/autonomous-machines/embedded-systems/jetson-orin/nano-super-developer-kit/) | Runs GPS-denied navigation (visual odometry, terrain matching) + AI reconnaissance pipeline. 67 TOPS for real-time inference. Ethernet to Pixhawk. |

**Subtotal compute: ~$249 / ~0.06 kg**

### 12. Cameras

| # | Component | Specification | Qty | Weight | Unit Price | Total | Link | Why This |
|---|-----------|---------------|-----|--------|-----------|-------|------|----------|
| 12.1 | ADTI 26S V1 + 35mm lens | 26MP APS-C, Sony IMX571, mechanical shutter | 1 | ~122g | $1,890.00 | $1,890.00 | [UnmannedRC](https://unmannedrc.com/products/26mp-26s-v1-aps-c-mapping-camera) | GPS-denied navigation camera. Mechanical shutter eliminates rolling shutter distortion at speed. 21.6 cm/px GSD at 2 km. Lightest 26MP APS-C option (122g with lens). |
| 12.2 | Viewpro Z40K 4K gimbal | 4K 20× optical zoom, 3-axis stabilized, 25.9MP | 1 | ~595g | $3,000.00 | $3,000.00 | [Viewpro](https://www.viewprouav.com/product/z40k-single-4k-hd-25-times-zoom-gimbal-camera-3-axis-gimbal-uav-aerial-photography-cartography-and-patrol-inspection.html) | AI reconnaissance camera. 2.7 cm/px GSD at 2 km max zoom. 103×58m FoV in 4K. 479g lighter than Viewpro A40 Pro. PWM/TTL/SBUS control compatible with ArduPilot. |

**Subtotal cameras: ~$4,890 / ~0.72 kg**

### 13. Communications

| # | Component | Specification | Qty | Weight | Unit Price | Total | Link | Why This |
|---|-----------|---------------|-----|--------|-----------|-------|------|----------|
| 13.1 | TBS Crossfire Nano RX | 915 MHz, long range RC receiver | 1 | ~2g | $30.00 | $30.00 | [GetFPV](https://www.getfpv.com/tbs-crossfire-nano-rx.html) | Long-range RC link (>40 km). Ultra-light. ArduPilot CRSF protocol support. |
| 13.2 | RFD900x telemetry modem (air) | 900 MHz, 1W, >40 km range, AES-128 | 1 | ~30g | $97.00 | $97.00 | [Droneyard](https://event38.com/product/rfd-900x-telemetry-set/) | MAVLink telemetry + mission commands. Encrypted. Long range. Pixhawk-native integration. |

**Subtotal comms: ~$127 / ~0.03 kg**

### 14. Power System

| # | Component | Specification | Qty | Weight | Unit Price | Total | Link | Why This |
|---|-----------|---------------|-----|--------|-----------|-------|------|----------|
| 14.1 | Tattu 6S 33Ah 350 Wh/kg semi-solid | 22.2V, 10C, 2216g each, XT90-S | 4 pcs | 8.86 kg total | $750.00/pc | $3,000.00 | [GenStattu](https://genstattu.com/tattu-semi-solid-state-350wh-kg-33000mah-10c-22-2v-6s1p-g-tech-lipo-battery-pack-with-xt90-s-plug/) | 4× in 2S2P → 12S 66Ah (2930 Wh). 350 Wh/kg is highest available density in production. 500+ cycle life at 90% retention. Modular — individual pack replacement. |
| 14.2 | Power distribution board + BEC | 12S input, 5V/3A + 12V/3A BEC outputs | 1 | ~25g | $30.00 | $30.00 | Various | Powers servos (5V HV), Pixhawk, GPS, RC receiver. |
| 14.3 | Wiring + connectors + battery bus | 10-12AWG silicone, XT90, series adapters, parallel bus bar | 1 set | ~450g | $80.00 | $80.00 | Various | 2S2P wiring: 2× series adapters + parallel bus bar. Redundant connectors. |

**Subtotal power: ~$3,110 / ~9.34 kg**

### 15. Catapult Interface

| # | Component | Specification | Qty | Weight | Unit Price | Total | Why This |
|---|-----------|---------------|-----|--------|-----------|-------|----------|
| 15.1 | Belly mounting rails | Aluminum rails for catapult carriage attachment | 1 set | ~150g | $50.00 | $50.00 | Interface between airframe and pneumatic catapult carriage. Quick-release on launch. |

**Subtotal catapult interface: ~$50 / ~0.15 kg**

### 16. Field Repair Kit

| # | Component | Specification | Qty | Weight | Unit Price | Total |
|---|-----------|---------------|-----|--------|-----------|-------|
| 16.1 | S2-glass patches | 6oz, 150×150mm pre-cut | 10 pcs | ~50g | $2.00/pc | $20.00 |
| 16.2 | Field epoxy kit | Aeropoxy PR2032/PH3630 fast, 4oz | 1 | ~120g | $25.00 | $25.00 |
| 16.3 | Repair tools pouch | Cups, gloves, sandpaper, scissors, tape | 1 | ~200g | $15.00 | $15.00 |
| 16.4 | Spare belly panels | Pre-manufactured (item 6.1) | 3 pcs | ~450g (stored) | $15.00/pc | $45.00 |

**Subtotal repair kit: ~$105 / ~0.37 kg carried**

## Weight Summary

| Category | Weight |
|----------|--------|
| S2 FG skins + ribs + stiffeners (cured laminate) | ~3.80 kg |
| Foam core (in sandwich panels) | ~0.45 kg |
| CF wing spar (both halves, cured) | ~0.20 kg |
| Structural hardware (fittings, fasteners, hinges) | ~0.45 kg |
| Belly panel + bumper (installed) | ~0.19 kg |
| Catapult belly rails | ~0.15 kg |
| Parachute system | ~1.06 kg |
| **Airframe subtotal** | **~6.30 kg** |
| Motor + ESC + propeller | ~0.43 kg |
| Servos (×5) | ~0.18 kg |
| Pixhawk 6X + GPS | ~0.06 kg |
| Jetson Orin Nano Super | ~0.06 kg |
| ADTI 26S V1 + 35mm lens | ~0.12 kg |
| Viewpro Z40K gimbal | ~0.60 kg |
| TBS Crossfire Nano RX + RFD900x air | ~0.03 kg |
| Power distribution + wiring | ~0.48 kg |
| **Electronics subtotal** | **~1.96 kg** |
| 4× Tattu 6S 33Ah 350 Wh/kg | **8.86 kg** |
| **TOTAL** | **~17.12 kg** |

Margin to 18 kg MTOW: **~0.88 kg** (for paint, antenna, miscellaneous hardware)

## Per-UAV Cost Summary

| Category | Cost | % |
|----------|------|---|
| Composite fabrics | $280 | 3% |
| Resin system | $127 | 1% |
| Foam core | $109 | 1% |
| Consumables | $125 | 1% |
| Structural hardware | $180 | 2% |
| Belly protection | $35 | <1% |
| Parachute system | $900 | 8% |
| Field repair kit | $105 | 1% |
| **Airframe subtotal** | **$1,861** | **17%** |
| Propulsion (motor + ESC + props) | $250 | 2% |
| Servos | $125 | 1% |
| **Propulsion + actuators subtotal** | **$375** | **3%** |
| Pixhawk 6X Mini Set | $313 | 3% |
| GPS M10 | $44 | <1% |
| Jetson Orin Nano Super | $249 | 2% |
| **Avionics subtotal** | **$606** | **6%** |
| ADTI 26S V1 + 35mm (navigation) | $1,890 | 17% |
| Viewpro Z40K 4K gimbal (reconnaissance) | $3,000 | 27% |
| **Camera subtotal** | **$4,890** | **45%** |
| TBS Crossfire Nano RX | $30 | <1% |
| RFD900x air module | $97 | 1% |
| **Comms subtotal** | **$127** | **1%** |
| 4× Tattu 6S 33Ah 350 Wh/kg batteries | $3,000 | 27% |
| Power distribution + wiring | $110 | 1% |
| **Power subtotal** | **$3,110** | **28%** |
| Catapult belly rails | $50 | <1% |
| **TOTAL PER UAV** | **$11,019** | **100%** |

### Cost Drivers

The cameras (45%) and batteries (28%) together account for 73% of per-UAV cost. The airframe material is only 5% ($641 for fabrics + resin + foam). The parachute system at $900 is 8% — significantly reduced from the $2,310 ballistic system in earlier drafts by switching from the Peregrine CO2 ballistic system to the simpler FW Recovery Bundle (canopy + pilot chute + deployment bag). The UAV performs planned parachute landings, not emergency deployments — no ballistic launcher needed.

## Tooling (One-Time)

| # | Component | Cost | Amortization |
|---|-----------|------|-------------|
| 9.1 | Fuselage mold set (FG/epoxy female, L+R halves) | $800 | 50+ pulls |
| 9.2 | Wing mold set (FG/epoxy female, upper+lower) | $600 | 50+ pulls |
| 9.3 | Tail surface molds (H-stab + V-stab) | $400 | 50+ pulls |
| 9.4 | Wing spar jig (aluminum + MDF fixture) | $200 | 100+ uses |
| 9.5 | Vacuum pump (2.5 CFM electric) | $150 | Permanent |
| 9.6 | CNC foam plug machining (outsourced) | $1,500 | One-time |
| | **Total tooling** | **$3,650** | |

## Ground Equipment (One-Time, Shared)

| # | Component | Cost | Notes |
|---|-----------|------|-------|
| G.1 | TBS Crossfire TX module | $100 | Shared across fleet, plugs into RC transmitter |
| G.2 | RFD900x ground station modem | $200 | Shared GCS telemetry module |
| G.3 | RC transmitter (e.g. RadioMaster TX16S) | $200 | If not already owned |
| G.4 | Pneumatic catapult (ELI PL-60 class) | $15,000-25,000 | Shared launch system; 108 kg, 2 transport cases |
| | **Total GCS equipment (excl. catapult)** | **$500** | |

## Labor

| # | Task | Hours (first 5 units) | Hours (at 100 units) | Rate |
|---|------|----------------------|---------------------|------|
| L.1 | Mold prep + release | 2h | 1h | Technician |
| L.2 | Fuselage skin layup + vacuum bag + cure | 8h | 5h | Technician |
| L.3 | Wing skin layup + vacuum bag + cure | 6h | 4h | Technician |
| L.4 | CF wing spar layup + cure | 3h | 2h | Technician |
| L.5 | Tail surface layup + cure | 3h | 2h | Technician |
| L.6 | Demolding + trimming | 4h | 2.5h | Technician |
| L.7 | Assembly (bond ribs, fittings, hardware) | 8h | 5h | Technician |
| L.8 | Electronics integration + wiring | 6h | 4h | Technician |
| L.9 | Parachute system install + test | 2h | 1.5h | Technician |
| L.10 | Finishing (fill, sand, paint) | 6h | 4h | Technician |
| L.11 | Quality inspection + flight test | 4h | 2h | Senior tech |
| | **Total labor per airframe** | **~52h** | **~33h** | |

## Fleet Cost — 5 Aircraft

| Item | Calculation | Cost |
|------|------------|------|
| **Tooling (one-time)** | Molds + jigs + CNC plugs + vacuum pump | $3,650 |
| **GCS equipment (one-time)** | TX module + RFD900x ground + RC transmitter | $500 |
| **UAV components × 5** | $11,019 × 5 | $55,095 |
| **Labor × 5** | 52h × 5 × $30/h | $7,800 |
| **Spare parts stock** | Extra belly panels, props, connectors | $600 |
| | | |
| **Total for 5 aircraft** | | **$67,645** |
| **Per aircraft (all-in, incl. tooling)** | | **$13,529** |
| **Per aircraft (excl. tooling, marginal)** | | **$12,699** |

**Note**: Catapult ($15,000-25,000) is listed separately as ground equipment — not included in per-aircraft cost. It's a shared infrastructure item amortized across operations, not per-unit.

### Cost Breakdown — 5 Aircraft

| Category | Amount | % |
|----------|--------|---|
| Cameras (×5) | $24,450 | 36% |
| Batteries (×5) | $15,000 | 22% |
| Airframe materials (×5) | $9,305 | 14% |
| Labor | $7,800 | 12% |
| Avionics + compute (×5) | $3,030 | 4% |
| Tooling | $3,650 | 5% |
| Propulsion + servos (×5) | $1,875 | 3% |
| Comms (×5) + GCS equip. | $1,135 | 2% |
| Spares + repair kits | $1,125 | 2% |
| Catapult interface (×5) | $250 | <1% |

## Fleet Cost — 100 Aircraft

At 100 units, bulk pricing and learning-curve labor savings:

| Item | Unit Price Change | Reasoning |
|------|------------------|-----------|
| S2 FG cloth | $7.50/yd (−28%) | Bolt pricing from AGY distributor |
| CF UD tape | $2.50/m (−47%) | 800m order |
| Epoxy resin | $65/qt kit (−20%) | 5-gallon drums |
| Foam core | $6.50/sheet (−29%) | Case quantity from Diab |
| Consumables | $80/set (−36%) | Roll quantities |
| Hardware | $140/set (−22%) | Batch CNC, bulk fasteners |
| Parachute | $700/unit (−16%) | Volume discount from Fruity Chutes |
| Motor AT4120 | $95 (−14%) | 100+ order from T-Motor |
| ESC ALPHA 60A | $95 (−14%) | 100+ order from T-Motor |
| Batteries | $650/pc (−13%) | Tattu bulk/OEM pricing |
| ADTI 26S V1 | $1,700 (−10%) | Volume pricing |
| Viewpro Z40K | $2,500 (−17%) | Direct OEM/volume |
| Pixhawk 6X Mini | $250 (−20%) | Holybro 100+ discount tier |
| GPS M10 | $33 (−25%) | Holybro 100+ discount |
| Jetson Orin Nano | $199 (−20%) | NVIDIA volume/module pricing |
| RFD900x | $85 (−12%) | Bulk order |
| Servos | $20/pc (−20%) | Bulk order |
| Labor | 33h × $30/h = $990 (−37%) | Learning curve, jigs, repetition |

| Item | Calculation | Cost |
|------|------------|------|
| **Tooling** | 2 mold sets (50 pulls each) + jigs + vacuum | $7,300 |
| **Airframe materials × 100** | Bulk-priced fabrics + resin + foam + consumables + hardware | $116,000 |
| **Parachute systems × 100** | $700 × 100 | $70,000 |
| **Propulsion × 100** | (95 + 95 + 25) × 100 | $21,500 |
| **Servos × 100** | $100 × 100 | $10,000 |
| **Cameras × 100** | ($1,700 + $2,500) × 100 | $420,000 |
| **Avionics × 100** | ($250 + $33 + $199) × 100 | $48,200 |
| **Comms × 100** | ($30 + $85) × 100 | $11,500 |
| **Power system × 100** | ($2,600 + $100) × 100 | $270,000 |
| **Catapult interface × 100** | $40 × 100 | $4,000 |
| **Repair kits × 100** | $80 × 100 | $8,000 |
| **Labor × 100** | 33h × $30 × 100 | $99,000 |
| **Spare parts stock** | Belly panels, props, misc | $8,000 |
| **Quality tools** | Ultrasonic tester, etc. | $2,000 |
| **GCS equipment** | 5 GCS sets at $500 each | $2,500 |
| | | |
| **Total for 100 aircraft** | | **$1,098,000** |
| **Per aircraft (all-in)** | | **$10,980** |
| **Per aircraft (excl. tooling, marginal)** | | **$10,883** |

### Cost Breakdown — 100 Aircraft

| Category | Amount | % |
|----------|--------|---|
| Cameras | $420,000 | 38% |
| Power (batteries + wiring) | $270,000 | 25% |
| Airframe materials | $116,000 | 11% |
| Labor | $99,000 | 9% |
| Parachute systems | $70,000 | 6% |
| Avionics + compute | $48,200 | 4% |
| Propulsion + servos | $31,500 | 3% |
| Comms + GCS | $14,000 | 1% |
| Tooling + quality tools | $9,300 | 1% |
| Repair/spares | $16,000 | 2% |
| Catapult interface | $4,000 | <1% |

### Scaling Comparison

| Metric | 5 Aircraft | 100 Aircraft | Savings at Scale |
|--------|-----------|-------------|-----------------|
| Per-aircraft total cost | $13,529 | $10,980 | −19% |
| Per-aircraft airframe | $1,861 | $1,160 | −38% |
| Per-aircraft cameras | $4,890 | $4,200 | −14% |
| Per-aircraft batteries | $3,000 | $2,600 | −13% |
| Per-aircraft labor | $1,560 | $990 | −37% |
| Tooling per aircraft | $730 | $73 | −90% |
| Parachute per aircraft | $900 | $700 | −22% |

Scaling savings are modest (19%) because cameras and batteries dominate cost and have limited bulk discount potential. The largest percentage savings come from tooling amortization (−90%) and labor learning curve (−37%).

### Parachute System Alternatives

The FW Recovery Bundle at $830 is the recommended baseline. For reference, other options:

| System | Price | Weight | Rated | Deployment | Pro | Con |
|--------|-------|--------|-------|-----------|-----|-----|
| **Fruity Chutes FW Bundle (recommended)** | $830 | 950g | 20 kg @ 15fps | Pilot chute + deployment bag (air-stream) | Proven, sized right, includes harness, repackable | 2-4 week lead time |
| Fruity Chutes Peregrine UAV 5 Light | $2,310 | 1,480g | 20 kg @ 15fps | CO2 ballistic ejection | Fastest deployment, works at zero airspeed | 2.8× more expensive, heavier, CO2 cartridge consumable |
| Foxtech Parachute + Ejector 20kg | $899 | 1,600g | 20 kg | Servo + spring | Cheaper than Peregrine | Designed for multirotor vertical eject, heavier, unproven for FW |
| Skycat X68 + IFC-84-SUL | ~$1,100 | 420g | 17 kg max | Skycat Fuse® | Lightest system, fast deployment | Max 17 kg — borderline for 18 kg MTOW |
| DIY: Rocketman 120" + custom deployment | ~$350 | ~600g est. | ~18 kg | Servo hatch + spring | Cheapest | Unproven for this weight class, 4 shroud lines only |

## References

1. S2-glass cloth: https://www.carbonfiberglass.com/product/6oz-s-glass-27-width-html/
2. CF UD tape: https://www.easycomposites.co.uk/250g-unidirectional-carbon-fibre-tape
3. Aeropoxy PR2032: https://www.aircraftspruce.com/catalog/pnpages/01-42135.php
4. PVC foam core: https://www.easycomposites.us/easycell75-closed-cell-pvc-foam
5. Fruity Chutes FW Bundle: https://www.unmannedsystemssource.com/shop/parachutes/fixed-wing-bundles/fixed-wing-recovery-bundle-44lbs-20kg-15fps/
6. T-Motor AT4120: https://store.tmotor.com/product/at4120-long-shaft-vtol-pusher-motor.html
7. T-Motor ALPHA 60A: https://store.tmotor.com/product/alpha-60a-12s-esc.html
8. APC 16×8E: https://www.apcprop.com/product/16x8e/
9. Holybro Pixhawk 6X: https://holybro.com/products/pixhawk-6x
10. Holybro M10 GPS: https://holybro.com/collections/gps/products/m10-gps
11. Jetson Orin Nano Super: https://www.nvidia.com/en-us/autonomous-machines/embedded-systems/jetson-orin/nano-super-developer-kit/
12. ADTI 26S V1: https://unmannedrc.com/products/26mp-26s-v1-aps-c-mapping-camera
13. Viewpro Z40K: https://www.viewprouav.com/product/z40k-single-4k-hd-25-times-zoom-gimbal-camera-3-axis-gimbal-uav-aerial-photography-cartography-and-patrol-inspection.html
14. TBS Crossfire Nano RX: https://www.getfpv.com/tbs-crossfire-nano-rx.html
15. RFD900x: https://event38.com/product/rfd-900x-telemetry-set/
16. Tattu 350Wh/kg 6S 33Ah: https://genstattu.com/tattu-semi-solid-state-350wh-kg-33000mah-10c-22-2v-6s1p-g-tech-lipo-battery-pack-with-xt90-s-plug/
17. Foxtech Parachute 20kg: https://store.foxtech.com/parachute-for-20kg-uav-airplanes/
18. Skycat X68: https://www.skycat.pro/shop/skycat-x68-3zdz9
19. Rocketman parachutes: https://www.the-rocketman.com/products/ultra-light-high-performance-drone-parachutes

## Related Artifacts

- Previous drafts: `solution_draft01.md` through `solution_draft06.md`
- Research artifacts: `_standalone/UAV_frame_material/00_research/UAV_frame_material/`
