Non-planar layer Fused Deposition Modeling (FDM) is any form of fused deposition modeling where the 3D printed layers aren’t flat or of uniform thickness. For example, if you’re using mesh bed leveling on your 3D printer, you are already using non-planar layer FDM. But why stop at compensating for curved build plates? Non-planar layer FDM has more applications and there are quite a few projects out there exploring the possibilities. In this article, we are going to have a look at what the trick yields for us.
Not many people will argue with flying RC airplanes is super fun. One big bummer is when a crash damages a part beyond repair. Sure, the RC pilot could keep buying replacement parts but doing so will add up after a while. RC plane builder and general guy with a cool name, [HuckinChikn], decided to build a hot wire foam cutter so making replacement wings would be quick and cheap.
The actual hot wire part is nothing special, just some wire pulled taut across a frame and a 24 vdc power supply pumping out current and heating the wire so it melts any foam in its path. The unique part of the build is that one side of the hot wire frame is secured in place and only allowed to pivot about that point. The other side of the frame traces an airfoil-shaped pattern. This setup allows [HuckinChikn] to make tapered wings. The difference between a straight wing and a tapered wing is similar to that of a cylinder and cone.
Check out the video after the break for a quick demonstration how easy it is to make a wing when you have the right tool!
It’s been a while since we looked in on a TED talk but this one is fantastic. [Yves Rossy] is interviewed about his jet-powered flight wing at the TED conference. He designed the unit as a form of personal flight. He straps it on, jumps out of a plane, then flies across the sky until he runs out of fuel. There’s no steering mechanism; it’s more of a fixed-wing hang glider plus jet turbine engines. But the pilot can affect the direction of the wing by moving his body.
We’ve embedded the video after the break. The first five minutes are all flight footage (which you’re going to want to watch… we specifically kept the banner image vague so as not to spoil it for you). After that, you’ll enjoy the interview where details about the hardware and its operation are shared.
The wing itself is about 2 meters across, hosting four kerosene-powered turbine engines. There’s about eight minutes worth of fuel on board, which [Yves] monitors with a clock while also keeping an eye on the altimeter. Landings are courtesy of a parachute, with a second on board as a backup. If things go badly–and they have as you’ll hear in the interview–an emergency release frees the pilot from the machine.
Want to build your own? Maybe this will get you started.
DARPA has awarded an extension to AeroVironment for their work on the Nano Air Vehicle project. The prototype seen above, called Mercury, is an ornithopter which means it flaps it’s wings. It is the first to show controlled hovering. Look closely, there’s no rudder or tail. Mercury uses the two wings for both lift and control. Ornithopters themselves aren’t new, we’ve even covered them before. Usually they use the flapping wings for propulson and a tail to steer as they travel like an airplane. We would really love to see some detail shots of Mercury.