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6 layers55 × 35 mmPilot, the printed circuit board in 3D

A functional, security conscious, Unmanned Aerial Vehicle based on the Firefly Class spacecraft Serenity from the 2002 show..

Size
55 × 35 mm
Copper layers
6
Thickness
1.6 mm
Parts
136
Nets
112
Pads
695
Tracks, vias
815, 64
Pours
11
Routed
Yes
KiCad
KiCad 9.0 (file 20241229)
Created
20 Apr 2026
Updated
7 Nov 2026

Overview

Pilot is an open-source printed circuit board by Stab-Rabbit-coding, from the Stab-Rabbit-coding/Serenity-UAV repository on GitHub, published under the CERN-OHL-W-2.0 licence. It is a 6-layer board of 55 × 35 mm with 136 parts on 112 nets, routed with 815 tracks and 64 vias.

It is built around the DP83825IRMQR, ISOW1044BDFMR and ISOW1412DFMR, with the BMP388, TPSM828224SILR and SM04B-GHS-TB among its other parts.

Main components

12

README

README.md

Serenity UAV

A flight-worthy, security-hardened EDF tilt-rotor replica of the Firefly-class ship Serenity

Hardware License: CERN-OHL-W 2.0 Docs License: CC BY-SA 4.0 Software License: MIT CAD: FreeCAD | OpenSCAD | Blender PCB: KiCad 9 Firmware: C | Python Status: Rev U — Phase 5 build

"Can't stop the signal, and can't take the sky from me."

Serenity UAV — isometric render of the full assembly

Isometric render of the Rev S assembly — port/bow/dorsal view. Predates the Rev S1g wing spar and Rev S4c nacelle geometry; re-render pending (see TODO.md §0.10).

Overview

Serenity UAV is a fully functional electric ducted fan (EDF) tilt-rotor aircraft engineered as an actual physical build of the Firefly-class transport Serenity (Joss Whedon, 2002) — every component here is fabricated or procured, not conceptual. A two-part SLS-printed hull (one-piece forward head+cargo section and one-piece aft middle+rear section) carries two tilting EDF nacelles, a belly cargo bay with powered winch and clamshell doors, and an 8-node cooperative avionics architecture with PACE (Primary/Alternate/Contingency/Emergency) failover across every flight-critical function.

The design is held to the same rigor as a certifiable aircraft: real mass/CG/load budgets (no "TBD" specs), FAA/FCC/NIST/IEC standards vetting on every design decision with any effect beyond cosmetics, redundant power and control paths throughout, and a zero-trust security model — every onboard message is signed, authenticated, and logged to hardware-enforced non-executable storage — engineered to keep operating correctly inside a 500 W/m² RF field. Avionics, comms, and software are built for reuse across other UAV/UGV/USV platforms, not just this airframe. See AGENTS.md for the full authoritative project policy that governs every design decision in this repository.

Nominal Mission Profile

  1. Take off VTOL.
  2. Land vertically with cargo bay open and load and secure a 4″ × 3″ × 3″, 8 oz payload.
  3. Take off VTOL with payload.
  4. Fly into a 500 W/m² broadband RF environment.
  5. Lower and release the payload from the cargo bay onto a platform.
  6. Identify a 4″ × 3″ × 3″ payload on a moving platform.
  7. Synchronize flight with the platform.
  8. Attach the payload to the hoist and lift it from the platform.
  9. Pull the payload into the cargo bay and close the clamshells.
  10. Exit the hazardous environment and return to origin.

Throughout the mission, the aircraft shall also:

  • Identify, categorize, log, and report rogue or unauthorized C2 commands or malicious logic from any transmitter, authorized or not.
  • Identify unauthorized or unsafe behavior from any onboard compute node.
  • Isolate the affected node(s), gracefully fail over its functions, and log/report to ground control — all while maintaining safety of flight.

Specifications

ParameterValue
Length24.0 in (609 mm)
Wingspan19.1 in (486 mm)
Height7.93 in (201.5 mm)
AUW — two cells + 8 oz payload (Rev T-SB)13.93 lbm (6,318 g), provisional (docs/flight_envelope.md)
AUW — Phase 11 (full system)not re-derived since the 64 mm / split-battery redesign
Payload capacity (minimum)8.0 oz (226 g) in a 4″ × 3″ × 3″ bay
Thrust — nacelles only20.90 lbf (9,480 g) = 4 × 83.60 ozf (2,370 gf), QF2822-2300KV at 24 V, 80 A ESCs
Thrust — Phase 11 rear EDF (cruise)~2.81 lbf (1,275 g) net after RCS bleed
T/W — nacelles only (hover)≈ 1.50 with payload (design floor 1.2; provisional pending mass truth)
T/W — Phase 11 (hover, nacelles only)not re-derived
Compute8× PocketBeagle 2 Industrial (AM6254), PACE failover
Onboard busesCAN FD, MIL-STD-1553C, RS-485, Ethernet RSTP ring
External commsFive C2 links: Wi-Fi 5 GHz, Zigbee 2.4 GHz, mLRS, SiK/MAVLink 915 MHz, 49 MHz AX.25
EMI design objective500 W/m² RF field, correct operation

Mass/thrust/T-W figures are the corrected 2026-08-22 baseline (the earlier 1.61 hover T/W used a stale 2,768 g AUW) and remain provisional until the bottom-up AUW ledger recompute closes — see current-specification/README.md and docs/WBS.md §0.10.1.

Project Status (2026-11-03)

Rev U, design and PCB layout. Nothing is fabricated or assembled; the physical build has not started. The path to first flight is in docs/FIRST_FLIGHT_READINESS.md; open work is in TODO.md, generated from the full record in WBS.md.

AreaState
AirframeSCAD shells at Rev S baseline, carried into Rev U; STL re-exports pending after the TACCO 60 × 35 mm change; cargo-shell mesh defect open
Nacelles50 mm Rev S4c is current; 64 mm tandem-EDF redesign (NAC-64-SERVO-01) with a servo-driven nozzle is designed and fit-closed, with pivot, CFD, mass, and bench gates open
Avionics PCBsPilot and TACCO placed with ERC 0 / DRC 0 before routing, on corrected 4.80 mm PB2 rails; routing and Gerbers open. Flight Engineer, Observer, and Commo Rev T need further PCB work
BusesFleet MIL-STD-1553C via the Holt HI-6138 on every Pilot and TACCO (2026-09-28)
CommsmLRS on a bare STM32WLE5JC; Wi-Fi USB module selection is a fab blocker; Commo becomes one standalone node (Rev T, 2026-09-29)
Firmwareserenity-cn Phase 6 done; serenity-fc Phase 6 stub; Phase 7 open
Ground stationSkipper in design; ground-side radio loadout decision open
BOMbom_revU published 2026-11-03 (carry-forward of bom_revT, 2026-09-28); avionics rows lag the 2026-10 PCB changes
Build guideHand-drawn pre-Rev-T art; rebuild open (task 1.5.6)

Subsystems

Airframe — hull, wings, and nacelles

Airframe

SLS-printed (DuraForm PA CF) hull with high-lift wings: in two sections (forward head+cargo and aft middle+rear), hollow-walled and foam-filled to the canonical Firefly outer mold line. Rev S1g gave the wing a fixed, bonded 20×16.3 mm carbon-fiber spar as its primary bending member, replacing the earlier rotating-shaft design.

Airframe README →

Landing Gear — vertical post and wire-brace legs

Landing Gear

Four corner legs pair a rigid CF-PETG post with spring and ductile wire braces, giving a deliberately progressive, field-replaceable failure mode rated for a 6 ft full-AUW drop.

Landing Gear Analysis →

Nacelles — tilting tandem EDF pods

Nacelles

Two tilting pods each carry a tandem 50 mm EDF pair behind an 11-fin stator, with a variable-area nozzle scheduled on measured tilt (−5° to +135° pivot; 0° = horizontal) and driven by one sub-micro servo per pod. Rev S4c hollowed the pods (−179 g/pair) and added hinged ESC bays with flush access covers on a 4×90° motor pattern; a 64 mm tandem-EDF redesign is in progress.

Nozzle-Drive Trade Study →

Powerplant — EDF thrust and power distribution

Powerplant

Four nacelle EDFs give 9.84 lbf combined hover thrust at a T/W of ≈1.14, fed by a 6S LiPo through the EMI-hardened Flight Engineer power distribution board.

Power Distribution →

Avionics nodes — Rev T+ build guide card 17

Avionics

Eight PocketBeagle 2 Industrial nodes in four PACE-redundant stacks handle flight control, comms, and payload functions, all with 5 kV galvanic isolation, TPM-backed signed logging, MIL-STD-1553C, and a standalone Commo radio node (Rev T), plus the Skipper ground control station.

Avionics README →

Bow Sensor Suite — nose vision, ToF, and laser pod

Bow Sensor Suite

The forward Observer node — camera, Time-of-Flight array, and an eye-safe laser indicator — in the nose pod handles obstacle avoidance and rough size/orientation sizing of the mission payload.

Observer Board →

Cargo Handling — belly clamshell bay

Cargo Handling — Observer

A belly clamshell cargo bay with a powered winch and hoist loads/releases an 8 oz payload in flight, guided by the downward-facing Observer node for close-in 3D imaging of the payload.

Cargo Winch Specification →


Table of Contents


Authoritative Project Instructions

The canonical workspace instructions and design policy are maintained in AGENTS.md. All contributors and automated tools (including AI assistants) shall follow the requirements and standards documented there (coding style, fabrication specs, licensing, and attribution). CLAUDE.md is a one-line pointer to the same file, kept for tooling that looks for that name.

The Nominal Mission Profile and Specifications above are the current design baseline. Full engineering detail for each subsystem lives in that subsystem's own README/doc — see the link on each card in Subsystems above. The narrative that used to live directly in this file (full Airframe/Powerplant/Avionics/Cargo Handling write-ups) is preserved verbatim, for historical reference, in archives/root-readme-deep-dive-2026-08-03/.


References


License

Licensed by Steve Griffing, PE(CSE), CISSP-ISSEP, CPP, according to what each file produces:

  • Hardware — and any code that defines, creates or renders hardware (OpenSCAD, KiCad files and scripts, FreeCAD, Blender, G-code/slicer profiles, and tools that write or render meshes/CAD/PCB) — CERN-OHL-W 2.0 (SPDX CERN-OHL-W-2.0). Full text: LICENSE (root) / LICENSES/CERN-OHL-W 2.0.
  • Code whose end result is software or firmware (firmware, device trees, ground software, analysis/verification/CI tools) — MIT (SPDX MIT). Full text: LICENSES/MIT.
  • Documents (Markdown, text, specifications, build guides, and all images — SVG, PNG, JPG, WebP, including renders produced by hardware tools) — CC BY-SA 4.0 (SPDX CC-BY-SA-4.0). Full text: LICENSES/CC-BY-SA 4.0.

See docs/attribution_and_licensing.md for the full policy, the per-subsystem LICENSE federation map, and the CERN-OHL-W "Available Component" treatment of upstream canonical-reference geometry. Revision U, November 2026.

Attribution

"Serenity Tiltrotor Drone Project — hardware CERN-OHL-W 2.0, software MIT, docs CC BY-SA 4.0, based on: · Serenity Firefly-class hull by misubisu (thingiverse.com/thing:7330462, CC BY-SA 4.0) · Variable-area EDF nozzle by BamJr (thingiverse.com/thing:2991269, CC BY 4.0) Include a link to the applicable license and indicate if changes were made."

Component License Map

ComponentOriginal AuthorSourceLicenseDerivative Notes
Hullmisubisuthingiverse.com/thing:7330462CC BY-SA 4.0 (Available Component under CERN-OHL-W 2.0)Scaled to 24 in, hollowed to 0.079 in (2.0 mm) CF-PETG shell, foam-filled
Nozzle mechanism conceptBamJrthingiverse.com/thing:2991269CC BY 4.0Iris petal concept reference; all Rev O/P/Q nozzle geometry original
Design (hardware/CAD/PCB)This project—CERN-OHL-W 2.0All original work: PCBs, mechanical/CAD, wiring
Design (docs/code/scripts)This project—CC BY-SA 4.0Firmware spec, tooling, build guides, this document

What This License Covers

Covered under CERN-OHL-W 2.0 (hardware):

  • 3D-printable hull, nacelle, and nozzle design files (STL/SCAD/FCStd)
  • PCB schematics and Gerber files for Pilot, TACCO, Flight Engineer, Commo, and Observer
  • Circuit diagrams, pinout tables, and wiring specifications
  • Mechanical drawings and assembly specifications
  • Any derived hardware shall carry CERN-OHL-W 2.0 (or a compatible license) and attribute all upstream authors

Covered under CC BY-SA 4.0 (documentation, code, scripts, non-hardware drawings):

  • Firmware architecture specifications and algorithm descriptions
  • This design document in all its revisions (A–R and beyond)
  • Build automation/tooling scripts and non-hardware SVG diagrams
  • Any derived works shall carry CC BY-SA 4.0 and attribute all upstream authors

Not covered / separate terms:

  • Third-party commercial components (EDFs, ESCs, PocketBeagle 2, etc.) — their own terms
  • SiK radio firmware — GPL-3.0
  • ArduPilot / QGroundControl — GPL-3.0
  • tpm2-tools / tpm2-tss — BSD-2
  • CPLD Verilog write-blocker firmware — separately MIT licensed
  • Proprietary flight controller firmware (your compiled code) — your terms
  • FAA/ICAO regulatory compliance is YOUR responsibility as operator

Patent Notice

This license does NOT grant rights to any patents held by component manufacturers or the design authors. The design uses standard open hardware interfaces (CAN FD, Ethernet, SDIO, SPI, I²C, MAVLink). If you commercialise products based on this design, conduct your own freedom-to-operate analysis. The write-blocker CPLD design implements append-only log enforcement consistent with log data protection principles in NIST SP 800-92 §4.4.2 [REF-NIST-004]; no patent claims are made on the implementation.

Forensic Evidence Integrity Note

The write-blocker and NX enforcement hardware described in this design are intended to support operational log integrity, not forensic evidence collection. They implement log data protection principles consistent with NIST SP 800-92 §4.4.2 [REF-NIST-004]. They are NOT certified forensic tools under NIST CFTT (Computer Forensics Tool Testing) Program specifications or SWGDE (Scientific Working Group on Digital Evidence) standards. Do not use this design as the sole mechanism for evidence preservation in legal proceedings without independent verification of the implementation against your jurisdiction's evidence handling requirements.

Parts

136
QtyValueFootprintReferences
23100nFCapacitor_SMD:C_0402_1005MetricC-3V3-HF, C-25M, C-50M, C-485-3, C-485-6, C-1553A, C-1553B, C-1553D, C-BARO1, C-BARO2, C-CAN3, C-CAN6, C-IMU1, C-IN3, C-RMII2-A2, C-RMII2-CRD1 +7
14100nFCapacitor_SMD:C_0201_0603MetricC-USB1-A11H1, C-USB1-A11H2, C-USB1-A33H1, C-USB1-A33H2, C-USB1-A33H3, C-USB1-A33H4, C-USB1-BKH, C-USB1-D04, C-USB1-D10, C-USB1-D11, C-USB1-D22, C-USB1-IO5, C-USB1-IO18, C-USB1-LXH
6330R@100MHzInductor_SMD:L_0402_1005MetricFB-485-G, FB-485-V, FB-CAN-G, FB-CAN-V, FB-USB1-A11, FB-USB1-A33
510uF 10V X5RCapacitor_SMD:C_0805_2012MetricC-485-2, C-485-5, C-CAN2, C-CAN5, C-IN2
51uFCapacitor_SMD:C_0402_1005MetricC-RMII2-A3, C-RMII2-CRD2, C-RMII2-CTD2, C-RMII2-IO3, C-TPM1
5SM04B-GHS-TBConnector_JST:JST_GH_SM04B-GHS-TB_1x04-1MP_P1.25mm_HorizontalCAN-FD, J-ETH-RMII2, J-ETH-USB1, MIL-1553, RS-485
410nFCapacitor_SMD:C_0402_1005MetricC-485-1, C-485-4, C-CAN1, C-CAN4
475RResistor_SMD:R_0402_1005MetricR-RMII2-BSR, R-RMII2-BST, R-USB1-BSR, R-USB1-BST
4M2.5 PGNDSerenity-Custom:MountingHole_2.7mm_M2.5_PGND_RingH1, H2, H3, H4
4TC1G00Serenity-Custom:Pulse_TC1G00_PulseChip_4.7x3.2mmT-RMII2-RX, T-RMII2-TX, T-USB1-RX, T-USB1-TX
310nFCapacitor_SMD:C_0201_0603MetricC-IMU2, C-RMII2-A1, C-RMII2-IO1
322uF 6.3V X6SCapacitor_SMD:C_0603_1608MetricC-3V3-IN, C-3V3-O1, C-3V3-O2
34.7kResistor_SMD:R_0201_0603MetricR-USB1-PME, R-USB1-PU, R-USB1-VBUS
210kResistor_SMD:R_0201_0603MetricR-TPM10, R-TPMCS
210nF 2kVCapacitor_SMD:C_1808_4520MetricC-RMII2-BS, C-USB1-BS
210uF 6.3V X5RCapacitor_SMD:C_0603_1608MetricC-USB1-A11B, C-USB1-LXB
2120RResistor_SMD:R_0603_1608MetricR-485T, R-CANT
215pF C0GCapacitor_SMD:C_0402_1005MetricC-USB1-XI, C-USB1-XO
24.7nF X2YSerenity-Custom:X2Y_0805_4TX2Y-CAN, X2Y-RS485
24.7uF 10V X5RCapacitor_SMD:C_0603_1608MetricC-USB1-A33B, C-USB1-BKB
255R 2%Resistor_SMD:R_0603_1608MetricR-1553N, R-1553P
2SMAJ33CADiode_SMD:D_SMATVS-1553N, TVS-1553P
2SRF2012-100YSerenity-Custom:Bourns_SRF2012_4TCMC-CAN, CMC-RS485
10RResistor_SMD:R_0805_2012MetricR-PGND
110kResistor_SMD:R_0402_1005MetricR-1553IRQ
110uF 6.3V X5RCapacitor_SMD:C_0805_2012MetricC-1553C
11uF 10VCapacitor_SMD:C_0402_1005MetricC-SPI5
12.2uHInductor_SMD:L_Murata_DFE201610PL-USB1
12.49kResistor_SMD:R_0201_0603MetricR-RMII2-AD0
1200RResistor_SMD:R_0402_1005MetricR-USB1-XO
120MHz CL20pFCrystal:Crystal_SMD_3225-4Pin_3.2x2.5mmY-USB1
124k 1%Resistor_SMD:R_0402_1005MetricR-USB1-RSET
125MHz 3.3VOscillator:Oscillator_SMD_ECS_2520MV-xxx-xx-4Pin_2.5x2.0mmX-25M
147uF 10V X5RCapacitor_SMD:C_1210_3225MetricC-IN1
150MHz 3.3VOscillator:Oscillator_SMD_ECS_2520MV-xxx-xx-4Pin_2.5x2.0mmX-50M
16.49k 1%Resistor_SMD:R_0201_0603MetricR-RMII2-RBIAS
1742792512Inductor_SMD:L_0805_2012MetricFB1
1AX88772EQFPackage_DFN_QFN:QFN-32-1EP_4x4mm_P0.4mm_EP2.9x2.9mmNIC-USB1
1BMP388Serenity-Custom:Bosch_BMP388_LGA-10_2x2mmBARO
1CDSOT23-SM712Package_TO_SOT_SMD:SOT-23TVS-RS485
1DP83825IRMQRPackage_DFN_QFN:Texas_RMQ0024A_WQFN-24-1EP_3x3mm_P0.4mm_EP1.9x1.9mmPHY-RMII2
1ESD2CAN24-Q1Package_TO_SOT_SMD:SOT-323_SC-70TVS-CAN
1HI-6138PCIFSerenity-Custom:Holt_HI-6138_QFN-48_6x6mm_P0.4mm_EP4.6mm1553-XCVR
1ICM-42688-PPackage_LGA:Bosch_LGA-14_3x2.5mm_P0.5mmIMU
1ISOW1044BDFMRPackage_SO:SOIC-20W_7.5x12.8mm_P1.27mmCAN-TR
1ISOW1412DFMRPackage_SO:SOIC-20W_7.5x12.8mm_P1.27mmRS485
1MF-PSMF035XFuse:Fuse_0805_2012MetricF-SPI
1Nano-Fit 4PSerenity-Custom:Molex_NanoFit_1x04_HorizontalPWR-IN
1PB2I-P1-2x18Serenity-Custom:PocketBeagle2_2x18_P1_TSM-DV-LCPB2-P1
1PB2I-P2-2x18Serenity-Custom:PocketBeagle2_2x18_P2_TSM-DV-LCPB2-P2
1PM-DB2791SSerenity-Custom:Xfmr_1553_SMD_0.40in_8pin1553-XFM
1SLB9672XU20Package_DFN_QFN:QFN-32-1EP_5x5mm_P0.5mm_EP3.6x3.6mmTPM
1SM06B-GHS-TBConnector_JST:JST_GH_SM06B-GHS-TB_1x06-1MP_P1.25mm_HorizontalJ-SPI
1TPD4E05U06DQARSerenity-Custom:TI_DQA0010A_USON-10_2.5x1.0mm_P0.5mmESD-SPI
1TPSM828224SILRSerenity-Custom:TI_SIL0010D_uSiP-10_2.0x2.5mm_P0.5mmU-3V3
1TSM-108-01-L-DVSerenity-Custom:Samtec_TSM-108-01-x-DVJ-PWM

Questions

How big is the Pilot PCB?

It measures 55 × 35 mm and has 6 copper layers, 1.6 mm thick.

What parts does the Pilot use?

136 parts, built around the DP83825IRMQR, ISOW1044BDFMR, ISOW1412DFMR and BMP388. The full list of its parts is on this page, with links to each part's symbol and footprint where PCBKit's library has them.

Where can I download the Pilot KiCad files?

From the Stab-Rabbit-coding/Serenity-UAV repository on GitHub, at the commit this page was made from: the board is avionics/kicad/Pilot/kicads/Pilot.kicad_pcb. PCBKit opens the board in the browser, with nothing to install.

Can I use the Pilot design in my own project?

Its repository publishes it under the CERN-OHL-W-2.0 licence: you may reuse it on that licence's terms (keep the author's notice, and for a copyleft licence share your changes alike).

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  • 2 layers90 × 30.3 mmIntegrated25, the printed circuit board in 3D

    Integrated25

    juicebox6030/Nova-Link

    NOVA-LINK is an open, low-latency wireless communication protocol and firmware stack designed for use in real-time live event environments.

    178 partsGPL-3.0
  • 2 layers70.6 × 50.3 mmTFUNIPAYLOAD01, the printed circuit board in 3D

    TFUNIPAYLOAD01

    ThunderFly-aerospace/TFUNIPAYLOAD01

    Universal interface for TF-ATMON sensor payload.

    81 parts1GPL-3.0
  • 6 layers35 × 40 mmRtk mini, the printed circuit board in 3D

    Rtk mini

    Poppy-Robotics/rtk

    CAN enabled, RTK GNSS module for robotics based on u-blox ZED-X20P

    75 parts
  • 4 layersESC R1, the printed circuit board in 3D

    ESC R1

    samvangysegem/esc-pcb

    A simple ESC designed in KiCad

    230 parts
  • 2 layers50 × 50 mmTFGPSLITE02, the printed circuit board in 3D

    TFGPSLITE02

    ThunderFly-aerospace/TFGPSLITE02

    Compact GNSS Module for Lightweight UAVs

    27 partsGPL-3.0