Aerial vehicle architectures for improved thrust efficiency and internal cooling

An airframe assembly for an unmanned aerial vehicle (UAV), the airframe assembly comprising:

• a top airframe assembly comprising a top foam airframe core at least partially enclosed within a top airframe shell;
• and
• a bottom airframe assembly comprising a bottom foam airframe core at least partially enclosed within a bottom airframe shell and coupled to the top airframe assembly, wherein:
• the top and bottom foam airframe cores form one or more rotor ducts;
• each rotor duct comprises an inlet and a diffusor outlet shaped to increase a thrust efficiency of a propulsion system for the UAV;
• the top airframe assembly comprises a metal heat sink assembly overmolded by the top foam airframe core;
• and
• the metal heat sink assembly is configured to cool at least power electronics of the UAV disposed between the bottom foam airframe core and the top foam airframe core.

A method for assembling an airframe assembly for an unmanned aerial vehicle (UAV), the method comprising:

• overmolding a top airframe shell with a top foam airframe core to form a top airframe assembly such that the top foam airframe core is at least partially enclosed within the top airframe shell;
• overmolding a bottom airframe shell with a bottom foam airframe core to form a bottom airframe assembly such that the bottom foam airframe core is at least partially enclosed within the bottom airframe shell;
• overmolding a metal heat sink assembly with the top foam airframe core such that a first side of the metal heat sink assembly faces the bottom foam airframe core and a second side of the metal heat sink assembly faces an inner surface of the top airframe shell, wherein the second side of the metal heat sink assembly comprises a dissipation surface comprising a plurality of folded fins;
• and
• attaching the top airframe assembly to the bottom airframe assembly, wherein:
• the top and bottom foam airframe cores form one or more rotor ducts;
• and
• each rotor duct comprises an inlet and a diffusor outlet shaped to increase a thrust efficiency of a propulsion system for the UAV.