Agricultural Aerial Systems Design
A 30-year exploration in unmanned aerial platforms, integrating design, prototyping and innovation in agricultural technology.
Overview
Falcon UAS is a long-term experimental project focused on the design and development of unmanned aerial systems for agricultural applications.
The initiative spans more than three decades of conceptual design, prototyping and system development, evolving alongside the global emergence of drone technologies.
This case study documents the evolution of the project from early aeronautical exploration to prototype development and international startup initiatives.
Early Exploration
The origins of Falcon UAS date back to experimental aeronautical concepts developed during the 1980s.
Initial work included:
• Lighter-than-air structures
• Aerodynamic exploration
• Conceptual flight systems
These early investigations laid the foundation for later development of fixed-wing UAV platforms designed for agricultural use.
The Agricultural Challenge
Large-scale agriculture requires efficient systems for:
• Crop monitoring
• Data collection
• Precision spraying
Traditional aerial solutions rely on manned aircraft, which involve:
• High operational costs
• Infrastructure dependency
• Limited flexibility
Falcon UAS explored an alternative based on autonomous aerial systems.
Concept Development
Over three decades, the UASystems project evolved through multiple design phases:
• Five aircraft design generations
• Structural and aerodynamic studies
• Payload system integration
• Operational concept development
Each iteration refined the platform’s performance, usability and scalability.
From Concept to Physical System
The project advanced into physical development through:
Construction of two full-scale prototypes
• Hangar-based assembly and testing
• Integration of structural and propulsion systems
This phase transformed theoretical design into tangible systems.
Design Principles
The Falcon UAS platform integrates:
• Distributed Propulsion
• Multiple engines for lift and stability
• Fixed-Wing Efficiency
• Optimized for long-range agricultural operations
• Modular Payload System
• Adaptable to different agricultural missions
• Operational Flexibility
• Designed for real-world field deployment
Field Operations Concept
The system was designed for practical agricultural use.
Key features include:
• Transport via trailer
• Rapid field assembly
• Decentralized deployment
• Minimal infrastructure requirements
This model allows scalable operations in rural environments.
Development Milestones
The Falcon UAS project progressed through several key milestones:
Phase 1 — Conceptual Research
Early aeronautical exploration and UAS concept definition.
Phase 2 — Design Iteration
Development of multiple aircraft configurations and system concepts.
Phase 3 — Prototyping
Construction of two functional prototypes and testing environments.
Phase 4 — System Consolidation
Integration of operational, structural and design components.
Phase 5 — Startup Development (2021)
Establishment of a company structure in Uruguay and preparation for investment.
Phase 6 — International Exposure
Participation in global innovation programs and competitions.
Startup Phase
In 2021, Falcon UAS evolved into an international startup initiative.
Activities included:
• Development of a business plan
• Investor outreach
• Regulatory exploration
• Engagement with aviation authorities
The project was presented to international innovation programs such as:
• FoodTech Challenge (UAE)
• Genius NY
Global Context
Today, agricultural drones represent a rapidly growing global industry.
Falcon UAS anticipated key aspects of this transformation, including:
• Autonomous crop monitoring
• Precision spraying systems
• Distributed aerial operations
The project stands as an early exploration of these technologies.
Design as a Driver of Innovation
Falcon UAS demonstrates how design can contribute to complex technological development.
The project integrates:
• Industrial design
• Visual communication
• System architecture
• Innovation strategy
This approach highlights the role of design beyond aesthetics, as a tool for system-level thinking.
Role & Contribution
Marcelo Capellaro
Co-Founder — Lead Designer
Responsibilities included:
• Aircraft conceptual design
• System architecture development
• Industrial design and visual identity
• Prototype development
• Innovation strategy
• Investor presentations
DronsAir
Marcelo Capellaro
Founder — Lead Designer
Responsibilities included:
• Aircraft conceptual design
• System architecture development
• Industrial design and visual identity
• Prototype development
• Innovation strategy
• Investor presentations
After the Falcon UAS experience, the info and contacts recolected over 3 decades, DronsAir made an upgrade in drones design with two variants: One for corners or boundaries, is a six propulsion e-motors with 2 rotors; the other model is a biplane in tandem, 8 e-motors, eVTOL 45º controled decolaje and landing, no airstrip needed, 180 litres of payload for extensions.
Reflection
DronsAir is not only an aircraft concept.
It is a long-term exploration of how design can engage with complex systems, evolving through time, constraints and technological change.
The project reflects the intersection of design, engineering thinking and innovation.