Experimental Evaluation of Energy Consumption and Acoustic Emissions in Sub-250 g Quadcopters with Added Tubular Propeller Enclosures

This paper investigates the impact of tubed propeller design on the energy efficiency and acoustic emissions of sub-250 g quadcopters. This study was motivated by the growing popularity of ultralight UAVs and the lack of experimental data addressing the trade-offs between noise, efficiency, and mass. Ten drone configurations with varying tube geometries and tip clearances were constructed using 3D-printed PLA+ frames and identical propulsion components. Experimental tests were conducted in a reverberation room to measure sound pressure levels and onboard energy consumption during hover. The results show that tubed configurations are 3–6.5 dB louder than untubed ones, with a noticeable shift toward higher frequencies. While tubes increased total power demand by 18–37% compared to the lightest design, they also reduced it by 3–17% relative to untubed drones of the same mass. The findings demonstrate that tubing improves aerodynamic efficiency only under same mass constraints and is most beneficial when mechanical protection is prioritized over noise and endurance.