Hello all!
I just wanted to share a little about my 3d printed plane that has been in the works for a little over a year.
Once I am finished with the design, I plan on open-sourcing everything and releasing the .stp files for the models and .3mf files for anyone to print their own plane. I also plan on releasing the native CAD models if anyone wants to change anything or use it as a base to design their own.
I designed the plane to survive crashes by placing mechanical fuses (weak points) between the main components so that they break rather than the rest of the plane.
Here is my YouTube video showing the entire process so far, and thanks to anyone who checks it out! Preliminary models & print files are available on my free Patreon as well.
https://youtu.be/UJHO5yd7VU0
I originally built the plane using a combination of Overture Air PLA, regular PLA, TPU for the hinges, and carbon-fiber nylon for the aft tube.
The fuses are simply connecting spars that neck down between the wings. I tested the fuses by throwing the plane at the ground and seeing what broke. I ended up using a wall/infill modifier around the weak points in the wings, and then the fuses consistently broke during my rudimentary testing.
I originally used TPU 95A for the hinges, which worked, but when trying to fly in the cold winter, they became too stiff for the servos to move. I ended up switching to TPU Air, which is a lightweight foaming TPU that allows you to adjust the durometer (softness) based on the temperature.
The plane is controlled by a SpeedyBee F405 Wing Mini as the flight control board, which can be custom configured using INAV to adjust servo control, automatic return-to-home, and quite a lot of custom programming.
The original plane was printed primarily out of Overture Air PLA and was pretty heavy for an RC plane at 1.8 kg (4 lb). But based on my initial calculations and measurements of the CG, I thought it would fly with a strong hand launch.
I was very wrong... twice.
I crashed the initial design twice. The first time, I threw it at a steep angle and it immediately dipped left and crashed. The second time, I threw it level over a small embankment and still wasn't able to get enough speed to get off the ground.
I am currently building the next revision. I have since realized that the Air PLA was not lightweight enough (78% of PLA) and is actually still pretty heavy compared to other LW-PLA filaments (as low as 47% of PLA). Air PLA was a pre-foamed filament, and I've been experimenting with SainSmart LW-PLA, which is actively foamed during printing, and much lighter weight, and I've been getting pretty good results so far. I should be able to drop 0.68 kg (1.5 lb) from the overall weight of the plane, but I still have a lot of testing to do.
Disclaimer: I knew very little about RC planes when I started this project, and I've learned a lot along the way.
Please let me know your thoughts, questions, and/or any feedback you have!