Design, manufacture and testing of a low-cost tilt-rotor UAV: a practical development case

Purpose – Unmanned aerial vehicles (UAVs) with vertical takeoff and landing (VTOL) capability are increasingly being used for parcel delivery, especially in areas lacking transport infrastructure. However, VTOL design presents distinct practical challenges. The purpose of this work is to present an accessible, low-cost design methodology for VTOL UAVs, addressing key technical hurdles relevant to resource-limited contexts. Design/methodology/approach – This article details the design, prototyping and initial flight validation of a small VTOL-UAV for parcel delivery missions. The approach integrates accessible design tools, evolutionary optimization methods for aerodynamic refinement and rapid prototyping using digital manufacturing and commercial off-the-shelf components. Experimental ground and flight tests were performed to evaluate design decisions and validate key assumptions. Findings – Early flight testing demonstrated that accurate weight prediction and propulsion system modeling are critical to avoiding operational bottlenecks such as insufficient payload capacity or throttle saturation. The prototype achieved stable, functional flight, supporting the validity of the design approach and identifying areas for further improvement. Social implications – The methodology supports the development of UAV solutions for aerial delivery in underserved rural regions, especially where conventional infrastructure is lacking or impractical. Originality/value – This study provides a comprehensive workflow for addressing practical design and manufacturing challenges in affordable VTOL UAVs. It offers guidance to practitioners and researchers by transparently integrating accessible tools and low-cost components.