4G-Controlled Surveillance Drone

Drone airframe — Completed 4G-controlled fixed-wing airframe.

Problem

Traditional radio control (RC) links for drones are limited by line-of-sight and distance, typically failing after a few kilometers. For long-range surveillance in remote or vast areas, a more robust and distance-agnostic communication system is required.

Solution

I developed a fixed-wing surveillance drone that utilizes 4G/LTE networks for control and telemetry. By leveraging cellular infrastructure, the drone can be operated from any location with internet access, effectively removing the distance limitations of conventional RC systems.

Airframe Design and Assembly

The airframe was custom designed and manufactured to accommodate the 4G module and all required components. It features a lightweight structure for optimal flight performance and endurance.

Materials Used

Styrofoam: Main airframe structure for buoyancy and impact resistance.
Carbon fiber & Balsa: Structural reinforcements between airframe sections.
EVA Bonding: Flexible and strong adhesive for airframe assembly.
Aluminium: Custom-fabricated landing gear.

Design & Assembly Workflow

Initial CAD modeling and component layout.
Custom cutting and shaping of styrofoam sections.
Reinforcement of critical stress points with carbon rods.
Bonding and alignment using EVA adhesive.
Integration of electronics and 4G modem.
Final assembly and COG balance checks.

Software & Connectivity

Control Software

ArduPilot: Robust autopilot firmware for autonomous navigation.
Mission Planner: Ground control station for mission planning.
QGroundControl: Real-time flight monitoring and telemetry.
MAVLink: Standard communication protocol for UAV data.

Network Architecture

The communication uses Peter Burke's framework, connecting the UAV to a ground computer via an AWS-hosted relay server for encrypted and stabilized communication.

Results

The project successfully demonstrated a proof-of-concept where the drone was controlled entirely from a PC over the internet. It achieved stable live video streaming and telemetry transmission, providing a reliable platform for autonomous long-range missions.

Project Gallery

Drone wings freshly cut in styrofoam — Drone wings cut from styrofoam.

4G-Controlled Surveillance Drone Model — The 4G-controlled fixed-wing UAV model.

Semi-assembled flight controller — Mateksys F765 flight controller.

Airfoil analysis and comparison in XFLR5.

Tech Stack

Hardware: Pixhawk Autopilot, 4G/LTE Modem, Raspberry Pi, Custom Airframe.
Software: ArduPilot, MAVLink, Mission Planner, Custom Python scripts.
Infrastructure: AWS-hosted relay server for encrypted communication.

Impact

This solution enables cost-effective, long-range aerial monitoring for applications such as pipeline inspection, border patrol, and environmental surveillance, significantly expanding the operational envelope of small UAVs.

Interested in custom long-range drone solutions?

Let's discuss your use case and how we can build a solution tailored to your needs.

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