ABOUT THE DIN

Full-Scale Modular RotorHub: Multi-Configuration Blade System with Actuated Pitch Control

HyperQ Aerospace

About the Company

Hyper Q Aerospace Holdings develops RotorHawk, an autonomous hybrid-electric compound coaxial rotorcraft built around a patented static, non-rotating main rotor shaft (granted patents in Australia, the US and Europe). The programme spans defence ISR and counter-UAS roles alongside bushfire detection, surf rescue and remote cargo delivery. The company works with UTS on control authority and vibration research, and is progressing toward a hover-demonstrated prototype at TRL 6.

Project Objective

Building on aeromechanical groundwork, the intern will design a full-scale reconfigurable rotor hub supporting four coaxial blade configurations (3×3, 4×4, 5×3, 7×5) and blade lengths from 2 m to 6 m. The design core is the Donut Lab 12-inch motor with provision to scale to 17-inch or 5-inch. The motor-to-hub coupling must minimise mechanical feedback while delivering near-instantaneous blade angular velocity response, and each blade grip is driven by an actuator arm for pitch control with zero fore-aft play. The work directly supports RotorHawk’s candidacy for the British Army’s Project NYX, the US Army T-REX programme, and ASCA-funded research.

Project Tasks

• Weeks 1–4: Develop SolidWorks hub solutions spanning all four blade configurations and the 2–6 m blade range, maximising 3D-printed content; design motor mounting interface with scaling provision; produce print-vs-purchase list and tolerance report.
• Weeks 5–9: Verify zero fore-aft play across all configurations; size certified off-the-shelf bearings for worst-case load (7×5, 6 m blades); design and model motor-to-hub coupling; prepare DMLS/FDM print files with HIP post-processing routes.
• Weeks 10–12: Design actuator arm pitch-control mechanism across all blade configurations; support bench rigidity testing; prepare inputs for Campbell diagram sign-off.
• Stretch goal: Preliminary swash plate design for this hub, sized against same configurations, maximising 3D-printed content.

Intern Skills

• SolidWorks — part/assembly modelling, drawing generation, tolerance stack-up; mechanical design for rotating safety-critical hardware.
• Mechatronic skills: actuator arm selection/integration, sensor mounting, basic control interfacing for blade pitch control.
• 3D printing — DMLS metal, FDM/SLS polymer and composite (e.g. continuous carbon-fibre nylon) including post-processing such as HIP.
• An eye for rigid, zero-play joints across every configuration and blade length.
• Comfortable picking up an existing design specification; safety-conscious around rotating hardware; self-directed between weekly check-ins.

How to apply

Eligible students (Australian citizens and permanent residents) apply via the online application form and submit a CV and motivation letter by 6 September 2026.