Giant Scale RC A350 Airliner Using Carbon Fibre And 3D Printing

Large scale RC aircraft are pleasure to see on the ground and in the air, but putting in the months of effort required to build them requires special dedication. Especially since there is a real possibility it could end up in pieces on the ground at some point.  [Ramy RC] is one of those dedicated craftsman, and he has a thing for RC airliners. His latest project is a large Airbus A350, and the painstaking build process is something to behold.

The outer skin of the aircraft is mostly carbon fibre, with wood internal framing to keep everything rigid. The fuselage and winglets are moulded using 3D printed moulds. These were printed in pieces on a large format 3D printer, and painstakingly glued together and prepared to give a perfect surface finish. The wing surfaces are moulded in flat section and then glued onto the frames. [Ramy RC]’s attention to detail is excellent, making all the control surfaces close as possible to the real thing, and retractable landing gear with servo actuated hatches. Thrust comes from a pair of powerful EDF motors, housed in carbon fibre nacelles.

This project has been in the works for almost 5 months so far and it looks spectacular. We’re looking forward to the first flight, and will be holding thumbs that is remains in one piece for a long time. See the video after the break for final assembly of this beast.

For the next step up from RC aircraft, you can always build your own full size aircraft in your basement. If you have very very deep pockets, get yourself a private hangar/workshop and build a turbine powered bush plane.

Thanks for the tip [tayken]! Continue reading “Giant Scale RC A350 Airliner Using Carbon Fibre And 3D Printing”

A DIY Functional F-35 Is No Simple Task

The advent of affordable gear for radio-controlled aircraft has made the hobby extremely accessible, but also made it possible to build some very complex flying machines on a budget, especially when combined with 3D printing. [Joel Vlashof] really likes VTOL fighter aircraft and is in the process of building a fully functional radio-controlled F-35B.

The F-35 series of aircraft is one of the most expensive defence project to date. The VTOL capable “B” variant is a complex machine, with total of 19 doors on the outside of the aircraft for weapons, landing gear and thrusters. The thruster on the tail can pivot 90° down for VTOL operations, using an interesting 3-bearing swivel mechanism.

[Joel] wants his model to be as close as possible to the real thing, and has integrated all these features into his build. Thrust is provided by two EDF motors, the pivoting nozzle is 3D printed and actuated by three set of small DC motors, and all 5 doors for VTOL are actuated by a single servo in the nose via a series of linkages. For tilt control, air from the main fan is channeled to the wing-tips and controlled by servo-actuated valves. A flight controller intended for use on a multi-rotor is used to help keep the plane stable while hovering. One iteration of this plane bit the dust during development, but [Joel] has done successful test flights for both hover and conventional horizontal flight.  The really tricky part will be transitioning between flight modes, and [Joel] hopes to achieve that in the near future.

The real Lockheed Martin F-35 Lightning II project is controversial because of repeated budget overruns and time delays, but the engineering challenges solved in the project are themselves fascinating. The logistics of keeping these complex machines in the air are daunting, and a while back we saw Marine ground crew 3D print components that they were having trouble procuring through normal channels.

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A Cyclonic Vacuum Cleaner On A Hacker’s Budget

Have you ever seen a product in the store and been shocked at what the manufacturer was trying to charge for it? Since you’re reading Hackaday, we can safely assume the answer to that question; building a homebrew version of some commercial product for a fraction of its retail price is practically a rite of passage around these parts. So it’s fitting that for his entry into the 2019 Hackaday Prize, [Madaeon] submitted the “DIYson”, an open source version of a popular high-end vacuum made by a British company who’s name you can surely guess.

As [Madaeon] explains on the project’s Hackaday.io page, the idea behind “cyclonic” vacuums is not particularly complex. Essentially, with a powerful enough blower and carefully designed chamber, the incoming air will spin around so fast that dust is pulled out by centrifugal force. The trick is getting it working on a small enough scale to be a handheld device. Especially given the energy requirements for the blower motor.

Luckily for the modern hacker, we’re living in the “Golden Age” of DIY. With a 3D printer you can produce plastic components with complex geometry, and thanks to a resurgence in remote controlled aircraft, powerful motors and high capacity lithium-ion batteries are easily obtainable. Powered by what’s essentially the hardware that would go into an electric ducted fan plane, the total cost of all the electronics for the DIYson comes in right around $60 USD. Even with a roll of printer filament added to the mix, you’re still comfortably at half the cost of the “name brand” alternative.

With some refinements, [Madaeon] hopes that this open source dust-buster will be a staple of labs and hackerspaces all over the world. Judging by the performance his early prototype shows in the video after the break, we know we wouldn’t mind having one.

Continue reading “A Cyclonic Vacuum Cleaner On A Hacker’s Budget”

A Safe, Ducted Drone With No Visible Blades

We love a good drone build here at Hackaday, but no matter how much care is taken, exposed propellers are always a risk: you don’t have to look far on the web to see videos to prove it. Conventional prop-guards like those seen on consumer drones often only protect the side of the propeller, not the top, and the same problem goes for EDFs. [Stefano Rivellini]’s solution was to take some EDFs and place them in the middle of large carbon fibre thrust tubes, making it impossible to get anywhere near the moving parts. The creation is described as a bladeless drone, but it’s not: they’re just well hidden inside the carbon fibre.

We’re impressed by the fact that custom moulds were made for every part of the body, allowing [Stefano] to manually create the required shapes out of carbon fibre cloth and epoxy. He even went to the trouble of running CFD on the design before manufacture, to ensure that there would be adequate thrust. Some DJI electronics provide the brains, and there’s also a parachute deployment tube on the back.

Whilst there’s no doubt that the finished drone succeeds at being safe, the design does come at the cost of efficiency. The power electronics needed are far more serious than we’d usually see on a drone of this size, to compensate for the extra mass of the thrust ducts and the impediment to the air-flow caused by the two 90° bends.

One of our favorite EDF drone innovations that we saw recently was this thrust-vectored single rotor device, a really unique idea that took some interesting control methods to implement.

[Thanks, Itay]

Continue reading “A Safe, Ducted Drone With No Visible Blades”

Plug Your Ears And Hop On This Jet-Powered EBike

Ah, the simple pleasures of a bike ride. The rush of the wind past your ears, the gentle click of the derailleurs as you change gears, the malignant whine of the dual electric jet turbines pushing you along. Wait, what?

Yes, it’s a jet bike, and its construction was strictly a case of “Why not?” for [Tech Ingredients]. They recently finished up a jet engine build using a hybrid design with electric ducted fans as compressors and fueled with propane. It was quite a success, and pretty spectacular, but left an embarrassment of riches upon its passing in terms of spare parts. The ducted fans, monstrous 90-mm 12s beasts, along with dual 150A ESCs found their way onto a mountain bike by way of a rear luggage rack. Pannier bags on each side hold the batteries, and a quick control panel went on the handlebar. The video below shows the build details and a couple of test rides, which show just how fast you can go with this setup. It may not be very practical compared to a more traditional hub motor, but it’s nowhere near as cool. Just be sure to wear your hearing protection.

Is this the first jet engine on a bike we’ve featured? Of course not. But for an impromptu build, it’s pretty impressive. Continue reading “Plug Your Ears And Hop On This Jet-Powered EBike”

Single-Rotor Drone: A Thrust-Vectoring Monocopter

We’re not entirely sure what to call this one. It’s got the usual trappings of a drone, but with only a single rotor it clearly can’t be called by any of the standard multicopter names. Helicopter? Close, but not quite, since the rotor blades are fixed-pitch. We’ll just go with “monocopter” for now and sort out the details later for this ducted-fan, thrust-vectored UAV.

Whatever we choose to call it — builder [tesla500] dubbed it the simultaneously optimistic and fatalistic “Ikarus” — it’s really unique. The monocopter is built around a 90-mm electric ducted fan mounted vertically on a 3D-printed shroud. The shroud serves as a mounting point for the landing legs and for four servos that swivel vanes within the rotor wash. The vanes deflect the airstream and provide the thrust vectoring that gives this little machine its control.

Coming to the correct control method was not easy, though. Thanks mainly to the strong gyroscopic force exerted by the rotor, [tesla500] had a hard time getting the flight controller to cooperate. He built a gimballed test stand to work the problem through, and eventually rewrote LibrePilot to deal with the unique forces on the craft and tuned the PID loops accordingly. Check out the results in the video below.

Some attempts to reduce the number of rotors work better than others, of course, but this worked out great, and we’re looking forward to the promised improvements to come.

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3D Printed Variable Area Jet Nozzle

If you’ve ever seen the back end of a military jet, you’ve likely seen variable area nozzles. They’re used to adjust the exhaust flow out of the rear of a jet engine during supersonic flight and while the afterburner is engaged. Commercial aircraft, with the exception of the Concorde, don’t need such fancy hardware since a static exhaust nozzle works well enough for the types of flying they’ll be doing. For much the same reasons, RC aircraft don’t need variable area nozzles either, but it doesn’t keep builders from wanting them.

Which brings us to this utterly gorgeous design by [Marco Colucci]. Made up of 23 individual PETG parts, this variable area nozzle is able to reduce its diameter by 50% with just a twist of the rotating collar. When paired with a hobby servo, this mechanism will allow the operator to adjust the nozzle aperture with an extra channel on their RC transmitter. The nozzle hasn’t flown yet, but a test run is being planned with a 40mm Electric Ducted Fan (EDF) motor. But thanks to the parametric design, it shouldn’t be a problem to scale it up to larger motors.

But the big question: does it have an effect on the EDF’s performance? The answer is, of course, no. This doesn’t actually do anything. An EDF motor has no need for this sort of nozzle, and even if you tried to fit this on a scale jet engine, it would melt in seconds from the exhaust temperature. This is purely a decorative item, to give the plane a more accurate scale look. To that end, it looks fantastic and would definitely be impressive on the back of a large scale RC military fighter.

If anything, [Marco] says he expects performance to be worse with the nozzle fitted. Not only is it adding dead weight to the plane, but restricting the air coming out of the back of the fan isn’t going to do anything but reduce thrust. But on the bright side: if it’s flying slower, it will be easier to see how awesome your adjustable nozzles look.

This isn’t the first time somebody’s tried to make an electric RC plane look like it’s packing a proper turbine, but it certainly might be one of the slickest. Only way to top this is to build an actual jet engine for the thing.

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