The CAD mistake that kills UAV airframes before first flight
Most UAV teams do not fail because they picked the wrong airfoil. They fail because the CAD is not manufacturable.
I see the same three issues on Fusion 360 airframes:
Surfaces that look smooth and are not G2. A pretty render hides zebra-stripe breaks. Those breaks become filler, extra ply, or a mold that will not pull.
Load paths that stop at a pretty bulkhead. If the spar cap does not run continuously into the fuselage hardpoint, the first hard landing shears the joint. Check the geometry, not the screenshot.
Wing geometry that was never checked as a flying surface. Twist, washout, and trailing-edge thickness get treated as styling. They are not.
If you are about to cut foam, print a mold, or send a STEP file to a composite shop — stop and review the CAD first. A two-hour markup is cheaper than a dead prototype.
That is the work I do at Apexwolfaerospace: structural layout, surfacing quality, and aero feasibility on your actual files.