Pyka Internship
SUMMER 2025, ALAMEDA, CA
BACKGROUND
Pyka is a company based in Alameda, CA that creates electric autonomous aircraft. I worked on their agricultural spray plane, the Pelican 2. The Pelican 2 uses a pitot-static probe mounted on each wing to measure the airspeed while in flight. However, the pitot tubes they use currently (the Simtec DPS-1) are expensive — around $500 per tube.
For this project, I aimed to create: 1) a pitot-static probe with drainage capabilities that was cheaper and easier to manufacture than the Simtec DPS-1, and 2) a driving rig that could comparatively test the two tubes. I explored the possibility of 3D printing pitot tubes in order to achieve these aims.
OUTCOMES
After going through 6 different versions, I developed a resin 3D-printed tube at 95% lower cost ($23/unit vs. $500/unit) than the Simtec DPS-1 (the aluminum tube) that matched the metal tube’s recorded airspeed within 1.6 m/s on average in a comparative drive test. Through my prototyping process, I identified key characteristics that impacted the accuracy of the speed readings such as the outer geometry of the tube and the size of the drainage hole.
To test my 3D-printed pitot tubes, I designed and mounted a test rig made with Unistrut on a Ford F-150 to compare airspeed readings of two pitot tubes simultaneously at ground speeds between 20-35 m/s. The structure elevated the tubes 7 feet above the roof of the truck to minimize the influence of the truck’s aerodynamic profile. It allowed the tubes to freely rotate so that they would be aligned with the airflow while driving.
The final prototype for the 3D-printed pitot tube
The dynamic pressure pathway for the tube
The static pressure pathway for the tube
The testing rig for the pitot tubes
The freely rotating test rig mount for the tubes
The data from the drive test showed that the 3D-printed pitot tube measured the airspeed within an average of 1.6 m/s (standard deviation = 0.8 m/s) of the DPS-1 readings, even at ground speeds up to 80 mph.
IMPACT
I acquired many new skills from this project. I learned what a pitot tube was, how to use a Formlabs Form 3+ 3D printer to create UV-cured resin parts, and how to safely glue things together using a methacrylate adhesive. I significantly improved my SOLIDWORKS skills by modeling the pitot tubes and the tube mounts for the test rig. I strengthened my Python skills and electronics skills by coding a program that recorded data from pressure sensors attached to the pitot tubes.
I was given a lot of freedom to decide the path of this project, so I made detailed specification tables for both the tube and the testing rig so I could objectively evaluate the success of both prototypes. I also organized two design reviews so I could get feedback and ensure I was headed on the right track. I learned the most from all of the Pyka employees who helped me — I talked to engineers on the mechanical, electrical, software, flight ops, flight test, and integration teams to bring the different components of my project together.
PROCESS
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Designing the Pitot Tube
Versions 4 and 5 of the tube’s 6 different iterations
Conducting bench testing to determine the maximum feasible tube drainage hole size
3D-printing the tubes out of resin with a Formlabs Form 3+ printer
Designing the Drive Test Rig
The first prototype of the truck mount
Writing the code and assembling the electronics to record the data from the pressure sensors
The tube mount went through 3 iterations (these are versions 1 and 2)
Assembling the testing rig
Conducting the Drive Tests
Driving the truck around was one of the most fun parts :)
The Python program running and recording data from the pressure sensors onto my laptop