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Flight Controller PCB

Custom UAV flight controller with sensor fusion and multi-rail power

Date Summer 2025
Board Size 50mm x 50mm
PCB Layers 6 Layer
Tools Altium Designer

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Overview

Custom flight controller PCB designed for flexible UAV applications with a compact form factor. The board features a 6-layer stackup (SIG - GND - PWR - SIG - GND - SIG) mounted on a 50mm x 50mm board, optimized for both performance and integration into various drone platforms.

The design includes comprehensive sensor fusion capabilities with IMU, barometer, and magnetometer interfaces, along with connector interfaces for mission-critical hardware such as VTX input, ELRS receiver, GPS module, ESC control, and connection to an external MPU.

Key Features

  • 6S (25V) battery input with multi-rail power distribution (5V, 12V, 3.3V, 1.8V)
  • Power multiplexer (ideal diode OR) for redundant USB-C 5V powering
  • USB-C interface for programming and power
  • Dual CAN bus interfaces for robust communication
  • Sensor fusion: IMU, Barometer, Magnetometer
  • STM32H7 microcontroller (100 LQFP package)
  • On-board SD card for data logging
  • Connector interfaces for VTX, ELRS, GPS, and ESC control
  • External MPU connection capability

Technical Specifications

MCU STM32H7 (100 LQFP)
PCB Layers 6-Layer (SIG - GND - PWR - SIG - GND - SIG)
Board Size 50mm x 50mm
Input Voltage 6S LiPo (~25V) or USB-C 5V
Power Rails 12V, 5V, 3.3V, 1.8V
Interfaces USB-C, Dual CAN, I2C, SPI, UART
Sensors IMU, Barometer, Magnetometer
Storage On-board SD Card

Design Details

Power Architecture

The board accepts 6S battery input (~25V) and generates multiple power rails for on-board and system-level electronics. A power multiplexer implements an ideal diode OR configuration for redundant USB-C 5V powering, ensuring reliable operation even during battery swaps or low-voltage conditions.

Sensor Integration

The flight controller integrates IMU, barometer, and magnetometer sensors for comprehensive attitude estimation and navigation. The sensor data is fused by the STM32H7 microcontroller for real-time flight control calculations.

Communication Interfaces

Dual CAN bus interfaces provide robust communication with ESCs and other peripherals. Additional interfaces include USB-C for programming and debugging, along with dedicated connectors for VTX (video transmitter), ELRS receiver, GPS module, and telemetry systems.