Airframe concept · RL1-100 Rev B

Relay One

A 1000 mm quadcopter that holds a Starlink Mini in the air for an hour. Drag to turn it.

MODEL BUILT FROM RELEASED DXF
WHEELBASE 1000 mm · PROPS 24 in
PAYLOAD STARLINK MINI, 1.10 kg
All-up weight12.2 kg
Hover, still air72 min
Plan for52 min
Thrust margin3.7 : 1
View
Exploded view0 %
Drag to orbit · scroll to zoom
Endurance52 min
Planned mission, after climb, wind and a 20 % reserve
Airframe + propulsion$2.3–4.5k
Battery and terminal already owned
Lead time4–8 wk
Carbon kit from China, assembled in-house
ComparableDJI M350
895 mm, 9.2 kg MTOW, ≈ $12k without payload

Why this is buildable, not a sketch

The model above is not an illustration. Every plate in it is extruded from the same DXF files that would go to the factory — same octagon, same bolt circles, same 52 holes in the upper deck.

The performance figures are not brochure numbers either. The hover model is momentum theory with its figure-of-merit calibrated against DJI's own published M350 data — 6.47 kg on 21-inch propellers for 55 minutes on 526 Wh. Applied to this airframe and the 1 554 Wh semi-solid pack already in the building, it returns 72 minutes of still-air hover at 12.2 kg.

Nothing here needs to be invented. The propulsion is an off-the-shelf integrated unit, the flight controller is a standard Pixhawk-class board, and the airframe is carbon plate and tube — the same construction as every agricultural drone flying today.

Already done

  • Full airframe specification, mass budget and power architecture
  • Seven A3 manufacturing drawings, general arrangement to spec sheet
  • Five DXF cut files, dimensioned and toleranced
  • Bill of materials with named suppliers and price bands
  • RFQ pack ready to send to five carbon shops

Still open

  • 1Weigh the battery — the design assumes 4.78 kg
  • 2Fix the arm hinge model, then match the deck hole patterns to it
  • 3NCAA registration and operating permit, started in parallel
Relay One RL1-100 Rev B · 1000 mm X-quad · 4 × Hobbywing XRotor X6 Plus G2 on 24 × 8 folding propellers · 12S 35 Ah / 1 554 Wh semi-solid pack · Starlink Mini on a 65 mm tower, rotated 45° to clear the propeller discs.
Geometry in this viewer is generated directly from the released cut files. Finish, fasteners and cable routing are indicative.