From Workshop to Competition: How Precision Helped UCLA DBF Reach the Top 10

At UCLA, innovation doesn’t just happen in the classroom, it’s built, tested, and flown. The student-led Design/Build/Fly (DBF) team recently soared to new heights, placing 10th out of over 100 teams in the AIAA Design/Build/Fly Competition with their electric-powered, remote-controlled aircraft. Behind the scenes, precision and speed were just as important as lift and thrust.

A quiet but powerful engine in their lab, the ELEGOO 20W Phecda Laser Engraver and Cutter, played a key role in streamlining their design and manufacturing process, allowing the team to build, test, and refine their aircraft with remarkable efficiency.

A proud team moment—group photo after completing all missions at the AIAA DBF Competition.

Building a Competitive Edge

Each year, DBF takes on a new challenge. This year, their mission is to design and fly a plane capable of releasing an autonomous glider mid-air and carrying a payload via removable pylons, all without sacrificing speed or structural integrity.

This complex engineering task required parts with high precision and fast turnaround—two things the ELEGOO laser cutter delivered flawlessly. From laser-cut wing and tail ribs, to custom jigs for assembly and even support boxes that elevate the aircraft during ground missions, the Phecda quickly became a cornerstone of the team’s fabrication workflow.

“The 20W Phecda Laser Engraver and Cutter has been an amazing tool for our engineering team, allowing us to cut and engrave different plane parts that require precise tolerancing, small details, or holes, with excellent quality. Its user-friendly interface gives all members of our team the opportunity to learn how to use the laser cutter quickly and effectively.” The team member shared.

Wings and tail ribs of the airplane made by the team using the Elegoo laser cutter

From Outsourced Delays to On-Demand Innovation

Before bringing the Phecda into their lab, DBF relied on shared laser cutters at UCLA Makerspace. This meant long wait times and limited access, often stretching a simple part cut into a 2–3 day delay. Now, with cutting power right at their fingertips, the team can go from CAD to physical component in just minutes.

This shift didn’t just save time, it transformed their workflow. With reliable cutting power and compatibility across materials like balsa wood and plywood, the team no longer needed to compromise on design due to equipment limitations. As a result, DBF was able to build, test, and refine their aircraft more effectively than ever before.

The picture shows the Bell Air made by DBF, flying in the competition.

Real-Time Learning Through Real Challenges

Innovation rarely comes without obstacles. The team faced challenges such as fragile balsa pieces breaking or stock materials exceeding the cutting bed size. But with creative problem-solving, like adjusting laser settings or trimming oversized stock, they navigated setbacks and kept moving forward.

Along the way, more team members became comfortable using the machine, building confidence in digital fabrication and sharpening practical engineering skills.

Flying High at Competition

Their months of hard work paid off at the AIAA competition. Despite a few weather-related setbacks, the team completed all three flight missions, with their glider landing in the 3-point zone and their design report ranking 2nd worldwide.

This marked their highest finish to date and reflected the impact of having streamlined, in-house fabrication tools, supporting faster iteration and more time focused on performance.

The team strides confidently into the competition arena, and their airplane soars in the competition.

Looking Ahead

The DBF team isn't slowing down. Their future goals include expanding their team, conducting more flight tests, and breaking into the global top 3. With laser cutters and 3D printers integrated into their workflow, they plan to continue iterating fast and learning faster.