Muhammad AdnanEngineering & designIdeas engineered. Solutions delivered.

Aerospace & UAVs

Engineering project

Hexacopter Flight Controller (Custom)

From-scratch heavy-lift hexacopter flight controller with triple-redundant IMU, GPS fusion, and LiDAR obstacle avoidance.

Flight ControllerIMUFreeRTOSMAVLink
Hexacopter Flight Controller (Custom) — engineering scope diagram Enlarge image
Project-specific scope and deliverables, illustrated from the engineering brief.
Hexacopter Flight Controller (Custom) — architecture diagram Enlarge image
Explanatory system architecture: inputs, engineering model and outputs.
Hexacopter Flight Controller (Custom) — workflow diagram Enlarge image
Explanatory workflow for the engineering analysis and validation process.

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Project brief

A high-performance flight controller designed from scratch for a 25kg payload capacity heavy-lift hexacopter UAV. Features triple-redundant IMU voting with fault detection, GPS/GLONASS/BeiDou multi-constellation GNSS fusion, LiDAR-based 3D obstacle avoidance, and MAVLink protocol compatibility with ArduPilot/PX4 integration. Used for precision agriculture and industrial inspection missions.

The project describes a custom UAV controller and its integration interfaces. Explanatory content does not add flight-test evidence or autonomy capabilities.

The engineering challenge

Combine redundant sensing, navigation, obstacle inputs, and propulsion outputs within a custom flight controller.

Engineering approach

  1. Use the stated IMU voting and navigation fusion for vehicle-state estimation.
  2. Connect obstacle and altitude information to flight-control decisions.
  3. Integrate telemetry, actuator outputs, and failsafe state transitions.

Features & capabilities

  • Triple-redundant IMU (ICM-42688P × 3) with majority voting fault detection
  • Multi-constellation GNSS: GPS, GLONASS, BeiDou, Galileo (HERE3 module)
  • 3D LiDAR obstacle avoidance: 20m range, 10Hz scan, automatic altitude hold
  • Barometric altimeter (MS5611) with temperature compensation
  • 6-channel ESC output: 400Hz PWM / DSHOT600 protocol
  • MAVLink 2.0 protocol: QGroundControl, MissionPlanner compatible
  • RTK-GPS ready: RTCM3 corrections via telemetry link for <2cm accuracy
  • Failsafe: RC loss, GPS loss, low battery — automatic return-to-home

Software & engineering tools

STM32H743VIT6, ICM-42688P × 3, HERE3 GNSS, TFmini-S LiDAR, FreeRTOS, MAVLink 2.0, Altium Designer

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