SUAS Breakdown

small Unmanned Aerial Systems

Unmanned aircraft: The term "unmanned aircraft" means an aircraft that is operated without the possibility of direct human intervention from within or on the aircraft. ^[1]
Unmanned aircraft system: The term "unmanned aircraft system" means an unmanned aircraft and associated elements (including communication links and the components that control the unmanned aircraft) that are required for the operator to operate safely and efficiently in the national airspace system. ^[2]
Small unmanned aircraft: The term "small unmanned aircraft" means an unmanned aircraft weighing less than 55 pounds, including the weight of anything attached to or carried by the aircraft. ^[3]
ESAD: Electronic Safe and Arm Device - a critical safety component used in an ordnance system, not specific to UAS. Provides electronic control of arming and firing functions with multiple safety interlocks.
ESAF: Electronic Safe Arming and Fire - legacy term more commonly used in UK contexts than ESAD. Both ESAD and ESAF are fundamental safety features in an ordnance system, ensuring proper arming sequences and preventing accidental detonation.
ELRS: Extended Low Rate of Spreading
ESCs: Electronic Speed Controllers
FPV: First Person View
IMU: Inertial Measurement Unit
GPS: Global Positioning System
GNSS: Global Navigation Satellite System
VTX: Video Transmitter
RX: Receiver
FC: Flight Controller
OSD: On-Screen Display

UAS Groups

Group	Weight (Max GTOW)	Normal Op Altitude	Max Speed	DoD Label	Common Roles	Example Systems
Soldier Borne Sensor (SBS)	< 0.55 lb	< 100 ft AGL	< 30 kt	Army SBS (not Group 1)	Individual soldier ISR, pocket/nano UAS	Black Hornet (example; any vendor may be selected)^[4]
Group 1	0 – 20 lb	< 1 200 ft AGL	< 100 kt	Micro / Small sUAS	Platoon ISR, FPV-strike, point recon	RQ-28A SRR, DJI Mavic 3 ^[5]
Group 2	21 – 55 lb	< 3 500 ft AGL	< 250 kt	Small sUAS	Company/Bn ISR, light kinetic, precision resupply	RQ-11 Raven, RQ-20 Puma, ScanEagle ^[6] ^[7]
Group 3	56 – 1 320 lb	< 18 000 ft MSL	< 250 kt	"Large" sUAS (still tactical)	Bn/brigade ISR, hybrid-VTOL cargo, comms relay	RQ-7 Shadow, V-BAT, RQ-21 Blackjack ^[8]
Group 4	> 1 320 lb	< 18 000 ft MSL	Any	Tactical UAS (not small)	Armed ISR, EW, extended-range strike	MQ-1C Gray Eagle, MQ-8B Fire Scout ^[9]
Group 5	> 1 320 lb	> 18 000 ft MSL	Any	Strategic UAS (not small)	HALE ISR/strike, deep-strike, maritime patrol	MQ-9 Reaper, RQ-4 Global Hawk, MQ-4C Triton ^[10]

Sub-system	Key parts	Why it's indispensable
Airframe / Structure	Frame plates or fuselage; arms/booms; landing skids/bumper	Holds everything together and sets thrust line / CG
Propulsion	Brushless motors (2205–2807 KV); matching propellers; ESCs (20–60 A, BLHeli-32)	Converts electrical energy into thrust and steering authority
Energy	Li-Po/Li-ion battery pack (4 S–6 S) / hybrid or fuel engine	Powers all onboard systems; sets endurance ceiling
Flight-control brain	IMU-equipped flight controller; GPS/GNSS module; barometer; magnetometer	Runs autopilot firmware; fuses sensor data; closes control loops
C2 / Telemetry	RC receiver (ELRS, Crossfire, DJI OcuSync); datalink radio; antennas	Operator commands in, health & video out
Power distribution & wiring	XT60/XT90 lead; silicone-insulated loom; power-distribution board	Safely routes high-current battery output to ESCs & avionics
Optional but common	FPV / EO-IR camera; video TX; companion computer; payload mount	Adds ISR or strike capability

	COTS Quad (DJI Mavic 3 class)	FPV Kamikaze (DIY 5″–7″)	Stick-frame Improvised
Frame	Injection-moulded, folding arms	5–7″ carbon X-frame	Pine / bamboo sticks; zip-ties
Motors	Integrated in arm	2306 / 2307 / 2807 6 S outrunners	Cheap 2306 1900 KV sets
Propellers	Folding 9–9.4″ 2-blade	5–7″ tri-blade poly-carbonate	Any 5″ nylon/carbon pair
ESCs	Integrated 4-in-1	45–60 A BLHeli-32 (singles or 4-in-1)	Same, heat-shrunk to stick arm
Battery	Smart 4 S 5000 mAh Li-Po (≈77 Wh)	6 S 1300–1800 mAh Li-Po	Recycled 6 S or parallel tool packs
FC firmware	DJI proprietary	Betaflight / iNav or ArduPilot	Same on low-cost F722 boards
RC / Video	DJI OcuSync 2.4 / 5.8 GHz	ExpressLRS RX + 5.8 GHz 1 W VTX	Crossfire or ELRS; VTX taped on
Typical payload	4 K gimbal cam; grenade drop-mod	3-D-printed nose with PG-7V or 40 mm HEDP; ESAD PCB	Stick spear, thermite charge, or small PG-7

Propellers – diameter + pitch must suit motor KV & voltage; wrong combo causes brown-outs or stalls.
Motors – 2306/07 outrunners deliver ≈1 kg thrust each on 6 S × 5″ props (enough for 0.5 kg warhead 15–20 km).
ESCs – BLHeli-32 flashed to 48 kHz reduces acoustic signature.
Frame material – carbon = rigid & low-RF; wood sticks are cheap, radar-transparent, disposable.
Battery chemistry – 6 S packs give power head-room for high-g dive-attacks.
ELRS / Crossfire – sub-gram RXs, 10–20 km L-o-S, frequency-hopping anti-jam.
ESAD add-ons – simple MOSFET safe/arm PCB triggered by spare FC output; dual-command logic prevents accidental detonation.

Pilot / Operator: Directly controls the aircraft (manual, semi-autonomous, or autonomous modes) and executes the mission profile.
Payload / Sensor Operator: Manages cameras, ISR sensors, or munitions; responsible for target acquisition, release, or data capture.
Mission Planner: Builds flight plans, waypoints, geofences, and contingency procedures; uploads mission data to the FC/GCS.
Launch & Recovery Crew: Handles physical launch methods (hand-launch, bungee, catapult, VTOL spool-up) and safe recovery or retrieval.
Maintenance Technician: Performs pre-flight checks, field repairs, firmware updates, battery health monitoring, and post-flight inspections.
ESAD Armorer: Implements Electronic Safe-and-Arm procedures for any explosive payload; verifies dual-command logic before arming.
Data Analyst / Intelligence Cell: Processes collected imagery/telemetry into actionable intelligence or battle-damage assessments.
Instructor / Standardization Pilot: Trains crews, maintains SOPs, and ensures compliance with regulatory and tactical standards.