Inside the vortex: How a 3D-printed drone captures unprecedented data

A team of storm chasers and scientists made history by successfully flying a 3D-printed drone into a tornado, collecting real-time data that could revolutionize severe weather research and forecasting.

One of the most memorable tornadoes of 2024 didn’t cause as much destruction as the storm that hit Sulphur, but it made history in another way.

A multi-vortex tornado near Duke became the first ever to be filmed from the inside, thanks to a team of weather researchers and storm chasers.

"This is the first time—and we’re actually getting data now as we’re flying," Erik Fox, founder and president of the National Storm Chaser Summit, said. "The best part of this is we’re working with Josh and Karen in the best project last year with their Doppler on Wheels—they actually could physically see our drone go into the tornado."

A Bold Experiment

The project started with a simple text message.

"I get this weird text one day, ‘Hey, ya know,’ his name was Nelson Tucker, and he goes, ‘Hey, I’m a meteorology student, and we have this idea we want to bring to you,’" Fox said.

With Fox’s help tracking storms, the team launched their experiment using 3D-printed quad drones equipped with sensors. The drones were carried by a fixed-wing aircraft before being guided directly into the tornado using augmented reality.

"We launched it from about four and a half miles away—as you can see here, we just absolutely take off towards it," Fox said.

As the drone neared the funnel, the team’s expert pilot confirmed they had a visual.

"As we go closer and closer, we start getting visual and the pilot Lou—Lou starts getting, ‘Oh, I see it—I see it, we’re good,’" Fox said.

Collecting Data from the Heart of the Storm

Once inside, the drone’s sensors measured temperature, humidity, wind speed, and pressure, all while GPS tracked its location.

"The first time I saw it, I was like, ‘How? Why? We just did this. This is groundbreaking, like never seen,’" Fox said.

The footage provided an unprecedented look at the inner workings of a tornado, something researchers hope will improve understanding of storm rotation.

"This isn’t going to be the last time you’re going to see the inside of a tornado from us," Fox said. "I can guarantee you at this point."

The team plans to use multiple drones in future storms, pushing the boundaries of tornado research even further.

Advancing Tornado Science

Fox and his specialized team of meteorologists, engineers, and pilots tested the capabilities of a drone designed to survive extreme wind conditions. The project, which started as an experimental collaboration, resulted in a groundbreaking achievement.

"This was a concept proof," Fox said. "We wanted to show we could not only get the data to the radar but also survive the tornado."

The team’s drone, built using 3D printing technology, features custom sensors that measure wind speed, pressure, and GPS tracking. Unlike traditional drones, this model is designed to withstand the turbulent forces of a tornado. "Everything about it is 3D-printed except for the batteries, some screws, and the processor chips," Fox explained.

The first successful deployment took place near Duke, Oklahoma, following multiple test flights in different storm conditions. The team worked closely with the Doppler on Wheels project, which confirmed the drone’s entry into the tornado. "They could physically see our drone go into the tornado," Fox said.

As the drone entered the vortex, it was lifted approximately 1,000 feet before stabilizing below FAA-regulated altitudes. It continued transmitting real-time data, offering insights into wind speeds exceeding 150 mph and vertical motion dynamics within the tornado. One surprising observation was a notable temperature drop, although the team is still verifying those results.

The success of the project marks a significant step forward in tornado research. Future plans include deploying multiple drones to gather 3D images of tornadoes from various angles, helping scientists understand why some storms produce tornadoes while others do not.

"If you can get this full 3D image at one time, you’re doing 35 years of tornado science in seconds," Fox said.

Despite its scientific significance, the project remains self-funded. The team is working to secure additional resources to continue their research and apply their findings to real-world applications, such as improving tornado warnings and strengthening building designs.

The research will be presented at the National Storm Chasers Summit, which will be held in Denver in 2026. Fox encourages aspiring meteorologists to pursue their passion. "Stay in school, absorb as much science and math as you can, and surround yourself with people who share your passion," he advised.

With continued advancements, Fox and his team hope their work will contribute to saving lives and better understanding one of nature’s most powerful forces.

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