From Prototype to Sky: The Struggles Behind Our First Successful Flight

As the deadline for the Flight Readiness Review (FRR) loomed over us on April 28th, tension was at its peak. Until then, we hadn’t even received the components for our final drone. All we had was our loyal prototype — affectionately named the “Cockroach” drone — which had seen more test flights and scrapes than we could count. While waiting for the long-delayed fabrication funds, we continued to tweak and refine our prototype.

Then came a whirlwind of a week.

On April 6th, we finally received the green signal for funding. By April 10th, we kickstarted the fabrication of our actual drone, which we named “Shadow.” Within a week, the drone went from sheets of carbon fiber and bags of wires to a fully assembled machine. It was an exhilarating experience — drilling frames, soldering components, tightening screws, fixing GPS modules — every step felt like building our own child from scratch. When we finally saw the assembled Shadow, we knew it was ready to fly.

April 18th was supposed to be the big day. We had secured flying permissions for the Watsa Stadium between 2 PM and 4 PM — a tightly controlled yellow zone due to our campus’s proximity to the city and the airport. After rounds of paperwork and coordination, we arrived with excitement brimming. All pre-flight calibrations were complete. Safety checks were done. Heartbeats quickened. The drone took off — and for a moment, it soared.

But our joy was short-lived.

The drone began to yaw erratically at a fixed position, refusing to stabilize. Disappointment hit us hard. But giving up? Never an option. That night, sleep was sacrificed for solutions. After extensive debugging and tests inside our lab, we found the issue, fixed it, and ran indoor validations.

April 20th — Take 2.

Same procedures. Same permissions. Same field. But this time, the outcome was different. “3… 2… 1… takeoff!” — and Shadow lifted off gracefully. No wobbles. No drifts. Just smooth, stable flight. The feeling? Pure euphoria. Cheers, screams, and relieved smiles filled the air. It was a moment that validated every sleepless night and every ounce of effort.

But there was no time to celebrate.

With just days to go before FRR and end-semester exams on the horizon, we had to complete our Proof of Flight Test. On April 23rd, we packed up Shadow, hopped on a scooty and a cab, and made our way to KCG College of Technology — a green zone safe for testing. With an extra 5 kg payload strapped on, we attempted flight, only to witness the frame begin to bend and a rotor tilt mid-air. 40°C heat bore down on us, and fixing it on the field was impossible.

We returned — exhausted, sunburnt, but determined. Two more sleepless nights followed. We troubleshooted. We reinforced the frame. We calibrated again. And on April 27th at 5 AM, we returned to KCG. This time, everything worked. Shadow flew with payload, met all test criteria, and landed safely.

We rushed back, compiled logs, edited videos, wrote documentation, and assembled the FRR submission. By 4 AM on April 28th, the document was complete. Reviewed and submitted by 6:30 AM.

No food. No rest. Just sheer drive.

This wasn’t just about flying a drone — it was about proving to ourselves that we could overcome chaos, pressure, and exhaustion to deliver when it mattered most. Shadow flew, and so did we — with pride, passion, and persistence.