lukas fleury
§03projects

On my own time.

012026

Ground-Up 5" Quadcopter Build

·Design + PID tuning
  • Built a 5-inch racing-style quadcopter end-to-end — starting from a 5" X-frame in CAD, then designing my own propellers and a custom flight-controller adapter to fit the electronics stack.
  • 3D-printed every frame component myself, iterating on fit and stiffness until the airframe held up to flight loads.
  • Selected and integrated the electronics: SpeedyBee F405 AIO flight controller, RS2205 brushless motors, FlySky radio link, and 3S 2200mAh LiPo packs.
  • Soldered every joint on the airframe myself — ESCs to motors, power distribution, receiver, and flight-controller harness — then configured and PID-tuned it in Betaflight to hit stable hover and controlled flight.
  • Crashed it, tuned it, flew it — each crash sent me back to the printer, the soldering iron, or Betaflight. Those iterations are what turned the airframe from wobble to stable hover.
5-inch custom quadcopter build — finished airframe
sound on
BetaflightPID TuningSolidWorks3D Print
022026 · ongoing

Valvetronic Dual-Exit Exhaust

·Personal build
  • Designed a custom valvetronic-style flow-diverter in SolidWorks — dual-exit exhaust with an RF-actuated valve for a cabin-controlled toggle between quiet and open modes.
  • Modelled the full exhaust routing from cat-back through the diverter to both exits.
  • Fabricating and installing the assembly end-to-end on my own vehicle — currently ongoing.
SolidWorks render of the full valvetronic dual-exit exhaust assembly
SolidWorksRF ActuationFabrication
032024

SkillsOntario Precision Machining

·Provincial Competition
Aluminum stock spinning in a three-jaw lathe chuck, turning tool engaged
  • 1st place — Waterloo Regional Precision Machining.
  • Represented at the SkillsOntario provincial competition.
  • Manufactured complex aluminum and steel parts under timed, high-tolerance constraints — mill, lathe, hand-tapping.
Manual MachiningPrecisionAward