1. ASSEMBLE: Hardware Integration Lab
Web Lab: garrf.in/kalam-zero-lab/droneassembly.html
This module provides structural assembly intuition for multi-rotor configurations. Students assemble each subassembly sequentially to understand mechanical balancing, center-of-gravity (CG), and weight constraints before physical flight.
Sequential Assembly Order
- Chassis Core: Fix 3K twill carbon-fiber central plates with CNC aluminum arm folding brackets. Ensure hexacopter structural symmetry.
- Brushless Motors: Mount 6x 380KV BLDC motors paired with 40A ESCs, adhering strictly to alternating Clockwise (CW) and Counter-Clockwise (CCW) rotation pairings.
- Landing Skids: Fasten 28 cm high-clearance tubular carbon skids beneath the lower plate to ensure clearance for sensitive payload pods on unpaved terrain.
- Power Distribution & 6S LiPo: Wire the high-current distribution harness and place the 6S 22.2V LiPo battery centrally to align with the airframe's neutral vertical axis.
- Autopilot Integration: Isolate the 32-bit triple-redundant flight computer using silicone dampeners. Mount dual RTK GPS masts on elevated stems to avoid RF interference.
- Payload Canister: Slide and lock the selected mission module onto the ventral quick-release rail system.
Critical Pre-Flight Math
- Max Takeoff Weight (MTOW): Must not exceed 7.8 kg. Base airframe + battery account for ~5.3 kg, leaving a maximum payload ceiling of 2.5 kg.
- Thrust-to-Weight Ratio: Combined motor thrust must exceed 2.0 : 1 to maintain control in turbulent rural wind profiles.
2. 3D HANGAR: Interactive Inspection & 6 Mission Drones
Web Lab: garrf.in/kalam-zero-lab/drone3d.html
The 3D Hangar allows 360° inspection, subassembly isolation, exploded views, and modular payload switching across the 6 specialized drone profiles:
The 6 Mission Configurations
- 1. Medical Emergency Drone: Active Peltier-regulated cold storage pod maintaining 2°C to 8°C for life-saving blood units, antivenoms, and vaccines.
- 2. Exploratory & Cultural Heritage Drone: High-resolution LiDAR puck paired with a 4K photogrammetry sensor for archaeological site reconstruction.
- 3. Agricultural Land Survey Drone: 5-band multispectral optical array delivering normalized difference vegetation index (NDVI) scans for precision farming.
- 4. Police & Vigilance Surveillance Drone: 30x optical zoom with Long-Wave Infrared (LWIR) dual FLIR camera and dual-strobe emergency lights.
- 5. Air-Post Rural Courier Drone: High-capacity cargo bay with servo-actuated drop hooks for last-mile delivery across rivers and hilly terrains.
- 6. High-Altitude Broadcast & Relay Drone: Omnidirectional high-gain dipole antennas for emergency telecom and live telemetry relay.
3D Manipulation Guide
- Rotate / Orbit: Left-click and drag across the viewport.
- Pan: Right-click and drag to translate the camera focus point.
- Zoom: Mouse scroll wheel to zoom into individual motors or circuit connectors.
- Exploded View: Use the slider to spread parts along their axes for internal inspection.
UAV Procurement Directory & BOM (September 2026)
Estimated component costs and vetted suppliers for educational institutions and young makers building this hexacopter platform:
| Subsystem | Component Specification | Est. Cost (INR) | Indian & Global Suppliers |
|---|---|---|---|
| Chassis | 680–850mm Carbon Hexacopter Frame | ₹8,500 – ₹12,000 | Robu.in, FlyRobo, UAVMarketplace |
| Propulsion | 6x 380KV BLDC Motors + 40A ESCs | ₹18,000 – ₹24,000 | T-Motor, Sunnysky, Robu.in |
| Avionics | 32-bit Triple-Redundant Autopilot + Dual RTK | ₹28,000 – ₹38,000 | CubePilot (Orange), Holybro, CUAV |
| Battery | 6S 22.2V 16000–22000mAh Semi-Solid LiPo | ₹16,000 – ₹22,000 | Tattu, Gens Ace, Orange LiPo |
| Telemetry | 2.4 GHz FHSS RC + 4G LTE Backup Link | ₹14,000 – ₹19,000 | RadioMaster, FrSky, Skydroid |
| Payloads | Modular Pods (Cold Pod / Multispectral / FLIR) | ₹36,000 – ₹44,000 | Garuda Aerospace, ideaForge, Local Lab |
*Note: Costs represent September 2026 indicative market procurement estimates for academic and prototype builds.
3. TRAVEL: Sovereign Flight Autonomy Lab
Web Lab: garrf.in/kalam-zero-lab/dronetravel.html
The mission dispatch simulator models real-world autonomous routing, battery discharge physics, and geofencing inside the official boundaries of India.
Operational Flight Rules
- Geofenced Sovereignty: Takeoff Base (Point A) and Destination (Point B) must reside strictly within Indian sovereign territory.
- 75 km Operational Periphery: Any mission target exceeding the 75 km blue radius circle triggers a range warning to prevent mid-air battery exhaustion.
- Failsafe RTL Threshold: Automatic Return-to-Land triggers if battery SoC drops to ≤ 25% during flight.
- Dual Optical Telemetry:
- Nadir 90° Top View: Downward ground mapping for terrain and landing spot verification.
- Forward FPV Camera: Horizon navigation for obstacle awareness along the transit vector.
Mission Completion: Once Point B is reached and cargo is dropped/delivered, the drone initiates safe automated descent or return corridor navigation.