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241 Articles

3D Printed Ribs For Not 3D Printed Planes

September 8, 2017 by 14 Comments

A few months ago, [Tom] built a few RC planes. The first was completely 3D printed, but the resulting print — and plane — came in a bit overweight, making it a terrible plane. The second plane was a VTOL tilt rotor, using aluminum box section for the wing spar. This plane was a lot of fun to fly, but again, a bit overweight and the airfoil was never quite right.

Obviously, there are improvements to be made in the field of 3D printed aeronautics, and [Tom]’s recent experiments with 3D printed ribs hit it out of the park.

If you’re unfamiliar, a wing spar is a very long member that goes from wingtip to wingtip, or from the fuselage to each wingtip, and effectively supports the entire weight of the plane. The ribs run perpendicular to the spar and provide support for the wing covering, whether it’s aluminum, foam board, or monokote.

For this build, [Tom] is relying on the old standby, a square piece of balsa. The ribs, though, are 3D printed. They’re basically a single-wall vase in the shape of a wing rib, and are attached to the covering (foam board) with Gorilla glue.

Did the 3D printed ribs work? Yes, of course, you can strap a motor to a toaster and get it to fly. What’s interesting here is how good the resulting wing looked. It’s not quite up to the quality of fancy fiberglass wings, but it’s on par with any other foam board construction.

The takeaway, though, is how much lighter this construction was when compared to the completely 3D printed plane. With similar electronics, the plane with the 3D printed ribs weighed in at 312 grams. The completely 3D printed plane was a hefty 468 grams. That’s a lot of weight saved, and that translates into more flying time.

You can check out the build video below.

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Building An Ultralight Out Of Foam In A Basement

August 14, 2017 by 50 Comments

[Peter Sripol] is something of a legend in the DIY RC aircraft crowd. He’s friends with Flite Test, and there he built an enormous RC cargo plane that could easily carry a small child aloft. Now, [Peter] is aiming a bit higher. He’s building an ultralight — a manned ultralight — in his basement. It’s made out of insulation foam.

Yes, this ultralight is constructed out of insulation foam, but you can think of that as just a skin. The real structure here comes from a wooden frame that will be fiberglassed. The design of this aircraft is an electric, twin-engine biplane. The relevant calculations have already been done, and [Peter] is already flying an RC scale model of this craft. So far, everything is not as sketchy as it could be.

As with any, ‘guy builds an airplane in his basement’ story, there must be a significant amount of time dedicated to the legality, practicality, and engineering of said plane. First off, the legality. [Peter] is actually building an ultralight under Part 103. The certifications for a Part 103 ultralight are much more lenient than the next step up in FAA-certified aircraft, a light sport or experimental aircraft. An ultralight is not required to have an airworthiness certification, and pilots of ultralights are not required to pass any tests of aeronautical knowledge or hold a medical certificate. Yes, legally, any moron can jump in an ultralight and fly. Think about that the next time someone brings up the Part 107 ‘drone’ certification.

Next, the practicality and engineering. [Peter]’s plane can weigh a maximum of 254 pounds, and should not be capable of more than 55 knots in full power level flight, while having a stall speed that does not exceed 24 knots. This is slow for a Cessna, but just about right for the gigantic remote-controlled planes [Peter] has already built.  A few years ago, [Peter] built a gigantic remote-controlled cargo plane out of what is basically foam board and a few aluminum tubes. The construction of [Peter]’s ultralight will be a highly refined version of this. He’s using foam insulation sheets for the body of the fuselage, reinforced with plywood and poplar struts. This foam and wood build will be wrapped with carbon fiber and fiberglass sheet, epoxied, and hopefully painted with flames on the side.

The use of poplar is a bit curious for an ultralight aircraft. For the last hundred years, the default wood for aircraft has been either spruce or douglas fir. The reason for this choice is the strength to weight ratio; spruce and douglas fir have the highest strength to weight ratio of any other wood. Poplar, however, is ultimately stronger and available at his local home improvement store, even though it does weigh a bit more. If [Peter] can keep the weight down in other areas, poplar is an excellent choice due to cost and availability. The video (below) is unclear, but we can only hope [Peter] has read up on the strength of aircraft frames and the orientation of the grain of each structural member.

This is the first video in what will be an amazing build series, and [Peter] hopes to get this thing up in the air by September. If you’re concerned about [Peter]’s safety, he’s also put up a GoFundMe page for a parachute. [Peter]’s going to fly this thing if you complain or concern troll or not, so donate a dollar for the parachute if you’re that concerned.

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The Ultimate FPV Cleans House

February 3, 2017 by 8 Comments

With much of the world in the doldrums of the winter, hackers are getting a bit stir crazy. [Notamed Closed] would much rather be outside flying his First Person View (FPV) quadcopters. Sure there are indoor drones, but [Notamed] wanted to keep grounded. He grabbed his R/C equipment, his Roomba, and of course an Arduino to build the ultimate FPV experience.

There aren’t many details on this build, but it’s not too hard to deduce what [Notamed] has done. He’s using a standard R/C transmitter and receiver. Instead of driving servos, the receiver plugs into an Arduino Uno. The Uno translates the PPM R/C signals to serial commands. Most Roomba’s include a serial port made especially for hackers. [Notamed] simply sends the proper iRobot Serial Command Interface (SCI) messages, and the robot is his to control.

The FPV side of things is a bog standard FPV camera and transmitter, sending standard definition video to his goggles. A GoPro is along for the ride to capture high-quality video.

Sure this is a quick hacked together build. All the parts are taped on to the Roomba. We’re sure this is on purpose. When the weather warms up, the R/C equipment goes back in the air, and the Roomba becomes just another vacuuming robot – once again a danger to pet messes everywhere.

Check out the video after the break.

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Remote Controlling A Dog

January 21, 2017 by 40 Comments

Until the industrial revolution, humans made use of animals to make our labor easier. This is still seen in some niche areas, like how no machine yet has been invented that’s as good at sniffing out truffles as pigs are. [William] has hearkened back to humanity’s earlier roots, but in a more modern twist has made something of a general purpose dog that could feasibly do any work imaginable. Now his dog is remote-controlled.

[William] accomplished the monumental task in a literally cartoonish fashion using the old trope of hanging a hot dog in front of something’s face to get them to chase it. The attachment point was fitted with a remote control receiver and an actuator to get the hanging hot dog to dangle a little bit more to the dog’s right or left, depending on where the “operator” wants the dog to go. [William]’s bulldog seems to be a pretty good sport about everything and isn’t any worse for wear either.

Believe it or not, there has been some actual research done into remote controlling animals, although so far it’s limited to remote-controlled cockroaches. We like the simplicity of the remote-controlled dog, though, but don’t expect to see these rigs replacing leashes anytime soon!

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The Hunt For Red October In A Bathtub

November 30, 2016 by 40 Comments

Anything can be a remote controlled airplane, and ‘copters – quad or not – simply beat the air into submission. Remote controlled cars are easy, and RC tanks can even shoot their guns. One type of vehicle has eluded remote control hobbyists to a large extent; building a remote control submarine is hard. Not only do you have buoyancy to worry about, but you also need a way to keep the dry parts dry, all while operating in an environment where radio doesn’t really work well.

[Ivan] has already built RC planes, but wanted to tackle a new challenge. He built an RC submarine, and he did it using the simplest household materials.

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How Many Drones Does It Take To Screw In A Lightbulb?

November 28, 2016 by 39 Comments

Imagine. There you are, comfortable in your lounge pants. Lounging in your lounge. Suddenly in the distance you hear a buzzing. Quiet at first, then louder. A light bulb goes on in your head.

You forgotten that you’d scheduled an Amazon drone repair service in partnership with The Home Depot and Dewalt. They break through the window, spraying you with shards. They paint the spots on the walls. Snap photos of the brands in your closet. Change the light bulbs. Place a bandaid on your glass wounds. Pick up the shards and leave. Repairing it on their way out.

Horrible.

Of course the first step before this dark future comes to be is to see if it can be done; which is what [Marek Baczynski] and a friend accomplished many broken light bulbs later. Using an off the shelf drone with three springy prongs glued to the top they try time and time again to both unscrew and screw in a light bulb. They try at first with a lighter drone, but eventually switch to a more robust model.

After a while they finally manage it, so it’s possible. Next step, automate. Video after the break.

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3D Printed R/C Lifeboat

November 27, 2016 by 3 Comments

Radio control boats usually bring up thoughts of racing catamarans, or scale sailing yachts. This build takes things in a slightly different direction. A radio controlled lifeboat with a built-in First Person View (FPV) transmitter. [Peter Sripol] used to be one of the awesome folks over at Flite Test. Now he’s gone solo, and has been cranking out some great builds on his YouTube channel. His latest build is a lifeboat loosely based on the totally enclosed lifeboats used on oil tankers and other seafaring vessels.

[Peter] designed the boat in 3D modeling software and printed it on his Lulzbot Taz 6. The files are available on Thingiverse if you want to print your own. The lower hull was printed in two pieces then epoxied together. Peter’s musical build montage goes by fast, proving that he’s just as good editing video as he is scratch-building R/C craft. Along the way he shows us everything from wiring up speed controls to cutting and soldering up a rudder. The final touch on this boat is a micro FPV camera and radio transmitter. As long as the boat is in range, it can be piloted through video goggles.

[Peter’s] boat is destined to be tested on an upcoming trip to Hawaii, so keep an eye on his channel to see how it fares in the monster waves!