Small Feathers, Big Effects: Reducing Stall Speeds With Strips Of Plastic

December 2, 2024 by Danie Conradie 18 Comments

Birds have long been our inspiration for flight, and researchers at Princeton University have found a new trick in their arsenal: covert feathers. These small feathers on top of birds’ wings lay flat during normal flight but flare up in turbulence during landing. By attaching flexible plastic strips – “covert flaps” – to the top of a wing, the team has demonstrated impressive gains in aircraft performance at low speeds.

Wind tunnel tests and RC aircraft trials revealed a fascinating two-part mechanism. The front flaps interact with the turbulent shear layer, keeping it close to the wing surface, while the rear flap create a “pressure dam” that prevents high-pressure air from moving forward. The result? Up to 15% increase in lift and 13% reduction in drag at low speeds. Unfortunately the main body of the paper is behind a paywall, but video and abstract is still fascinating.

This innovation could be particularly valuable during takeoff and landing – phases where even a brief stall could spell disaster. The concept shares similarities with leading-edge slats found on STOL aircraft and fighter jets, which help maintain control at high angles of attack. Imitating feathers on aircraft wings can have some interesting applications, like improving control redundancy and efficiency.

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Stripping GoPros To The Bone For Model Rocketry

December 1, 2024 by Danie Conradie 11 Comments

The small size of action cameras has made them a great solution for getting high-quality experimental footage where other cameras don’t fit. GoPros are [Joe Barnard]’s camera of choice for his increasingly advanced rockets, but even the smallest models don’t quite fit where he needs them. They also overheat quickly, so in the video after the break, he demonstrates how he strips and customizes them to fit his required form factor.

[Joe] starts out with a GoPro HERO10 Bones, which is a minimalist version intended for FPV drones. He likes the quality of the 4K 120 FPS video and the fact that he can update the settings by simply holding up a QR code in front of the camera. The case appears to be ultrasonically welded, so careful work with a Dremel is required to get it open. The reveals the control board with an aluminum heat sink plate, and the sensor module on a short ribbon cable. For minimal drag[Joe] wants just the lens to poke out through the side of the rocket, so he uses slightly longer aftermarket ribbon cables to make this easier.

The camera’s original cooling design, optimized for drone airflow, meant the device would overheat within 5 minutes when stationary. To increase the run time without the need for an external heat sink, [Joe] opts to increase the thermal mass by adding thick aluminum to the existing cooling plate with a large amount of thermal paste. In an attempt to increase heat transfer from the PCB, he also covers the entire PCB with a thick layer of thermal paste. Many of the video’s commenters pointed out that this may hurt more than it helps because the thermal paste is really intended to be used as a thin layer to increase the contact surface to a heat sink. It’s possible that [Joe] might get better results with just a form-fitting thermal block and minimal thermal paste.

[Joe] is permanently epoxying three of these modified cameras into his latest rocket, which is intended to fly at Mach 3, and touch space. This may look like a waste of three relatively expensive cameras, but it’s just a drop in the bucket of a very expensive rocket build.

We’ve seen GoPros get (ab)used in plenty of creative ways, including getting shot from a giant slingshot, and reaching the edge of space on a rocket and a balloon.

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Electrostatic Puck: Making An Electret

December 1, 2024 by Danie Conradie 24 Comments

You might have heard of electrets being used in microphones, but do you know what they are? Electrets produce a semi-permanent static electric field, similar to how a magnet produces a magnetic field. The ones in microphones are very small, but in the video after the break [Jay Bowles] from Plasma Channel makes a big electret and demonstrates it’s effects.

Electrets have been around since the 1800s, and are usually produced by melting an insulating material and letting it solidify between two high-voltage electrodes. The original recipe used a mix of Carnauba wax, beeswax, and rosin, which is what [Jay] tried first. He built a simple electric field detector, which is just a battery, LED and FET, with an open-ended resistor on the FET’s gate.

[Jay] 3D printed a simple cylindrical mold and stuck aluminum foil to the outer surfaces to act as the electrodes. He used his custom 6000:1 voltage transformer to hold the electrodes at ~40 kV. The first attempt did not produce a working electret because the electrodes were not in contact with the wax, and kept arcing across, which causes the electric charge to drop off. Moving the aluminum electrodes the inner surfaces of the mold eventually produced an electret detectable out to 10 inches.

This was with the original wax recipe, but there are now much better materials available, like polyethylene. [Jay] heated a a block of it in the oven until it turned into a clear blob, and compressed it in a new mold with improved insulation. This produced significantly better results, with an electric field detectable out to 24 inches.

[Jay] also built an array of detectors in a 5×5 grid, which he used to help him visualize the size and shape of the field. He once pulled off a similar trick using a grid of neon bulbs.

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Tailwheel Trainer Go-Cart To Avoid Wrecked Planes

December 1, 2024 by Danie Conradie 15 Comments

Taildraggers remain a popular configuration for small aircraft, but they come with a significant risk during ground handling: ground loops. If the tail gets too far off course, it can swing around completely, often damaging or destroying aircraft if a wing hits the ground. Avoiding ground loops requires good rudder and brake control, and there currently isn’t a good way to learn it without getting into an actual aircraft. [Trent Palmer] is a pilot and who has been thinking about this problem for a few years, so he built a 3-wheeled electric go-cart to help pilots train their ground handling.

The cart is controlled exactly like a taildragger, with a pair of rudder pedals connected to the single steerable via cables, and springs to add some response delay. Independent hydraulic brakes on each main wheel, operated by toe pedals, further simulate the control on many aircraft. The main wheel are controlled with a throttle lever, with a differential to allow them to rotate at different speeds. The cart is unforgiving, and requires constant corrections with the pedals to keep it going straight.[Trent] had few pilot and non-pilot friends try out the cart, and even the experienced tailwheel pilots got into ground loop. It might be bit too sensitive, but everyone agreed that mastering this cart would significantly improve ground handling skills in actual aircraft.

Repairing a damaged aircraft can cost several thousand dollar, so a cheap training tool like this could prove invaluable flight schools and even individual pilots. [Trent] doesn’t have big plans for commercialization, but we wouldn’t be surprised if it goes that way.

Taildraggers are especially popular as bush planes, with many tracing their heritage from the humble Piper J-3 Cub. We’ve seen some extreme extreme modern bush planes, like [Mike Patey]’s Scrappy and Draco builds. Continue reading “Tailwheel Trainer Go-Cart To Avoid Wrecked Planes” →

Experimental Drone Flies Like A Bird

November 25, 2024 by Danie Conradie 11 Comments

Most RC planes follow a simple control scheme: elevators for pitch, rudder for yaw, and ailerons for roll. This one-to-one mapping keeps things straightforward, and fewer actuators means less weight. But nature has other ideas. Birds achieve flight control through complex, coordinated movements where different body parts can affect multiple degrees of freedom simultaneously. Now, researchers at EPFL have brought this biological approach to robotics with the LisEagle, a drone featuring morphing wings and tail that demonstrate remarkable stability.

All the control surfaces and actuators — All the actuators!

The LisEagle packs seven different actuation methods alongside its nose-mounted motor. Three of these control the bird-like wingtips and spreading tail, while the remaining actuators handle more conventional controls: independently twisting wing bases (similar to ailerons) and a tail assembly that combines elevator and rudder functions in its vertical stabilizer.

Testing took place in controlled indoor conditions, with the maintaining position in front of an open wind tunnel. Optical position tracking provided closed-loop feedback and power was provided via a tether to minimize weight. A PID flight controller orchestrated all seven actuators in concert, achieving impressive stability even when faced with induced turbulence or being poked with a stick. In a demonstration of redundancy, the researchers deliberately disabled the twisting wing mechanisms, and the aircraft maintained control using just its wingtips and tail.

The team went further, employing Bayesian optimization to find the most efficient actuator combinations. This revealed potential energy savings of up to 11%, with optimal configurations varying based on airspeed as lift requirements changed.

While research into the flight mechanisms of bees, bats and birds might not immediately translate to practical applications, it deepens our understanding of flight control principles. Don’t be surprised if morphing wings become a more common sight in future aircraft designs.

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Modular Multi-Rotor Flies Up To Two Hours

November 24, 2024 by Danie Conradie 28 Comments

Flight time remains the Achilles’ heel of electric multi-rotor drones, with even high-end commercial units struggling to stay airborne for an hour. Enter Modovolo, a startup that’s shattered this limitation with their modular drone system achieving flights exceeding two hours.

The secret? Lightweight modular “lift pods” inspired by bicycle wheels using tensioned lines similar to spokes. The lines suspend the hub and rotor within a duct. It’s all much lighter than of traditional rigid framing. The pods can be configured into quad-, hex-, or octocopter arrangements, featuring large 671 mm propellers. Despite their size, the quad configuration weighs a mere 3.5 kg with batteries installed. From the demo-day video, it appears the frame, hub, and propeller are all FDM 3D printed. The internal structure of the propeller looks very similar to other 3D-printed RC aircraft.

The propulsion system operates at just 1000 RPM – far slower than conventional drones. The custom propellers feature internal ring gears driven by small brushless motors through a ~20:1 reduction. This design allows each motor to hover at a mere 60 W, enabling the use of high-density lithium-ion cells typically unsuitable for drone applications. The rest of the electronics are off-the-shelf, with the flight controller running ArduPilot. Due to the unconventional powertrain and large size, the PID tuning was very challenging.

We like the fact this drone doesn’t require fancy materials or electronics, it just uses existing tech creatively. The combination of extended flight times, rapid charging, and modular construction opens new possibilities for applications like surveying, delivery, and emergency response where endurance is critical.

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Transforming Drone Drives And Flies

November 22, 2024 by Danie Conradie 8 Comments

Vehicles that change their shape and form to adapt to their operating environment have long captured the imagination of tech enthusiasts, and building one remains a perennial project dream for many makers. Now, [Michael Rechtin] has made the dream a bit more accessible with a 3D printed quadcopter that seamlessly transforms into a tracked ground vehicle.

The design tackles a critical engineering challenge: most multi-mode vehicles struggle with the vastly different rotational speeds required for flying and driving. [Michael]’s solution involves using printed prop guards as wheels, paired with lightweight tracks. An extra pair of low-speed brushless motors are mounted between each wheel pair, driving the system via sprockets that engage directly with the same teeth that drive the tracks.

The transition magic happens through a four-bar linkage mounted in a parallelogram configuration, with a linear actuator serving as the bottom bar. To change from flying to driving configuration the linear actuator retracts, rotating the wheels/prop guards to a vertical position. A servo then rotates the top bar, lifting the body off the ground. While this approach adds some weight — an inevitable compromise in multi-purpose machines — it makes for a practical solution.

Powering this transformer is a Teensy 4.0 flight controller running dRehmFlight, a hackable flight stabilization package we’ve seen successfully adapted for everything from VTOLs to actively stabilized hydrofoils. Continue reading “Transforming Drone Drives And Flies” →