Toward next-generation logistics UAVs: a foldable square-frame drone with modular payload capacity

Purpose A foldable square drone prototype uses the latest structural aerodynamics, energy management and adaptive control to make it practical and reliable for engineering. The design aims to create an unmanned aerial vehicle (UAV) that can be tilted and reconfigured, is lightweight, durable and payload-efficient. Design/methodology/approach The foldable square-frame drone is made of lightweight materials, has a telescopic arm structure and is built in modules to make it more versatile, smaller and last longer. The prototype has a hybrid cargo-handling system, an energy-efficient power system and a foldable frame that makes it easy to carry and improves performance during air transport operations. Findings The foldable square-frame drone worked well in both structural strength and flight stability. The telescopic arm mechanism made it easy to switch between compact and extended configurations, which made the device easier to carry and improved its aerodynamic balance. The drone was able to carry a payload of up to 1.5 kg with very little structural deformation (less than 5 mm). Tests of the flight showed that it could last for up to 25 minutes without a load and 12–15 minutes with one. The dual payload system was able to handle different types of objects while staying stable. Overall, the design struck a good balance between weight, performance and versatility, proving that it was suitable for real-world multi-purpose UAV uses. Research limitations/implications You can switch the drone from compact mode to full-scale mode by pulling out the telescopic arms by hand. In the future, servo-driven actuators will be used to make the transformation process automatic. The multi-section-transformable-UAV model by D'sa and Papanikolopoulos (2019) used hinge actuators to change the shape of the UAV while it was flying. This is similar. Because the drone can fold up, it can go from compact transport mode to operational mode in 40 seconds, which makes it easier to deploy quickly. Practical implications The foldable square drone can be used for many things in everyday life. According to Otto et al. (2018), its structural flexibility makes it easier to deliver lightweight packages, medicines and emergency kits to areas that are far away or have been hit by a disaster. In farming, the drone collects soil samples and moves fertilizer between fields on its own, using Ouyang et al. (2019) UAV-wireless sensor network integration methods. It's great for checking power lines, wind turbines and bridges because it's easy to move and stays put. New studies back up this adaptability. Sheth (2025) and Lee et al. (2025) assert that modular UAV frameworks and morphing-wing technologies enhance mission flexibility and longevity. Social implications The foldable drones are good at balancing portability, endurance and stability. The modular frame can handle mechanical stress when it's full, the distributed energy system keeps the power steady and the hybrid cargo-handling system can handle a wide range of loads. The square foldable drone is a useful, environmentally friendly and flexible choice for both civil and industrial UAV uses, as these results show. Originality/value The proposed folding square-frame drone is unique in its mechanical flexibility, light weight and modularity. It lacks a hard structure like other drones. Instead, its telescopic arms allow it to be packed in a tiny place and fly steadily by modifying rotor spacing. The dual payload system can handle both flexible and rigid loads without tools. Aluminum 6061-T6 is stronger and lighter, making it endure longer and work better. This design works for logistics, farming and emergency response UAVs. Artificial intelligence and renewable energy systems can be added to its scalable platform.