Low-cost Unmanned Aircraft Systems have proven to be extremely useful for tracking and mapping coherent atmospheric structures. These aircraft systems are often required to alternate between dynamic, non-uniform sampling and deterministic trajectories, which makes VTOL aircrafts especially suitable for these applications. Outlined is the process by which an autonomous VTOL aircraft weighing less than 10 kg and powered by a hybrid engine is designed and fabricated. The preliminary design of the aerodynamic shell is overviewed. Design requirements for the aircraft are then listed, followed by design and analysis of individual components and mechanisms within the structure in order to inform material selection. The fabrication process of the aircraft is then described, followed by the design and fabrication of a 4-axis CNC foam cutter needed to cut the aerodynamic surfaces of the aircraft out of EPP foam. Lastly, further work to be done on the CNC foam cutter and the Aircraft is listed.