“Small and light drone platforms, usually below 249 grams, have revolutionized the drone industry by their cheap unit price and lighter regulatory requirements. Remote Aero wants to combine these properties with the range and speed of airplanes to allow for scalable situational awareness over the 4G network. With the help of Aero EDIH, we have developed a light carrier board that houses all the necessary electronics and sensors needed for such an aircraft, enabling long range flight with minimal risk to people and property on the ground”, says Alexander Sandström, CEO & Co-founder, Remote Aero.
Challenges
Remote Aero aimed to introduce a safe drone concept weighing less than 250 g, which required significant weight reduction across all subsystems. The existing avionics carrier board (version 3 from the EOS – Eyes On Scene – project) worked well in a 900 g fixed‑wing drone but was too large and heavy for the target weight.
The challenge was to design a new, smaller, and lighter carrier board that retained critical functionalities such as power management, communication, video processing, and flight control, while reducing component count, board area, and mass. Remote Aero engaged Aero EDIH to validate this concept and establish a clear path toward a sub‑250 g Unmanned Aerial Vehicle (UAV).
Solutions
RISE engineers developed CarrierBoard04a using Altium Designer, based on the previous 03a design. To save space, the LTE modem (Telit LE910Cx) was integrated directly onto the board following Telit’s hardware design guidelines. The battery configuration was changed from 3S to 2S with an external balancing charger, allowing removal of the cell‑balancing circuitry. Additional weight savings were achieved by replacing connectors with solder pads and removing legacy circuits such as flight termination, USB multiplexer, and Ethernet.
At the same time, new features requested by Remote Aero were implemented: seven separate JST‑GH servo connectors, onboard high‑power LED lanterns, a magnetic charging connector with safety disconnection after take‑off, and a tactile power switch accessible through the fuselage. Component placement was optimized for heat dissipation and assembly ease. The investment combined Aero EDIH support with customer funding for production and assembly.
Results and Benefits
CarrierBoard04a was produced in 10 units, with two assembled by Elektronikproduktion i Kinna AB. Despite added functionalities, the board area was reduced by approximately 20% and the weight by 30%, enabling progress toward the sub‑250 g drone target.
The integrated LTE modem simplified wiring and reduced failure points, while modular servo connectors improved maintainability. Thermal layout enhancements increased reliability. These improvements provide Remote Aero with a validated technical foundation for lightweight UAV offerings, supporting regulatory compliance and market acceptance.
Perceived Social and Economic Impact
A UAV weighing less than 250 g falls under a lighter risk category in EU drone regulations, which simplifies operational requirements near people and infrastructure compared to heavier classes. This reduces operational costs, eases licensing and training requirements, and accelerates market adoption for safe small drones in applications such as inspection and rapid data collection.
The project strengthens Remote Aero’s business case and contributes to regional innovation and supply chain development in Swedish electronics manufacturing.
Lessons Learned
Do’s: It proved highly beneficial to integrate communication modules such as LTE directly onto the carrier board, as this saved weight and reduced complexity. Optimizing the battery strategy by switching to a 2S configuration with external balancing simplified the design and eliminated unnecessary circuits. Early planning of component layout for heat dissipation and accessibility ensured reliable operation and easier assembly. Collaboration with technology providers and research partners, such as Telit and RISE, was essential for achieving a robust design within the given constraints.
Don’ts: Avoid retaining legacy connectors and circuits that no longer serve a critical function, as they add unnecessary weight and complexity. Do not underestimate the mechanical and placement challenges of high‑power LED lanterns and multiple servo connectors; these require careful planning from the start. Finally, never overlook safety considerations for charging interfaces—ensure electrical disconnection after take‑off to prevent short circuits in case of water landings.
”Lightweight drones are important for many reasons and in this project the main carrier PCB was optimised for future new generation of lightweight drones”, says Per Bröms, Innovation Lead, Aero EDIH.
