PDS Research pioneers adaptive mounting system for next-gen drone design
Preliminary CAD render of the Sky Warden front assembly showcasing the TPU-based mounting system, with early battery pack and central locking hub placement.
At PDS Research Foundation, our projects evolve through the creative momentum of engineers solving real-world problems in real time. This week, we’re celebrating a critical hardware milestone in the Sky Warden drone platform—thanks to the steady, inventive work of Zachary Ruschak.
Zach’s latest contribution centers on the front arm mounting system, a structural component key to Sky Warden’s modular build. What makes his design stand out is its material intelligence: it’s engineered to be printed in TPU (thermoplastic polyurethane) or a high-elongation filament, chosen for its ability to flex and rebound.
This allows the drone’s arms to compress and lock into place, enabling rapid field deployment while maintaining strength and adaptability.“
The design is going well. I’m looking forward to working on the surfacing for the shell next.
— Zachary Ruschak
In the next phase of development, Zach will:
- Finalize the locking mechanism for the front mount
- Begin modeling the rear assembly structure
- Design the motors and theoretical mounting plates to support system-level integration
Each step builds toward a more complete, test-ready prototype that can withstand the demands of real-world aerial deployment.
Detailed view of the TPU-compatible arm brackets designed for compression-locking functionality within the Sky Warden’s modular frame.
At PDS, engineering progress isn’t just measured in parts printed or CAD files rendered—it’s about how each new solution brings us closer to systems that serve and adapt. Zach’s work on Sky Warden reflects the precision, curiosity, and vision we’re proud to support.
Stay tuned for more updates as our drones—and the engineers behind them—continue to take flight.
