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The purpose of this paper is to present the preliminary design of a medium altitude long endurance (MALE) unmanned aerial vehicle (UAV), focusing on the interaction between the aerodynamic and the structural design studies.

The classic layout theory was used, adjusted for the needs of unmanned aircraft, including aerodynamic calculations, presizing methods and CFD, to estimate key aerodynamic and stability coefficients. Considering the structural aspects, a combination of layout, finite element methods and custom parameterized design tools were used, allowing automatic reshapes of the skin and the internal structural parts, which are mainly made of composite materials. Interaction loops were defined between the aforementioned studies to optimize the performance of the aerial vehicle, maximize the aerodynamic efficiency and reduce the structural weight.

The complete design procedure of a UAV is shown, starting from the final stages of conceptual design, up to the point where the detail design and mechanical drawings initiated.

This paper presents a complete view of a design study of a MALE UAV, which was successfully constructed and flight-tested.

This study presents a complete, synergetic approach between the configuration layout, aerodynamic and structural aspects of a MALE UAV.