80cm foamboard/3D printed hybrid 3D aerobatic plane


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My 3D printed/foamboard hybrid RC 3D plane with 80cm wingspan.

All stl files and foamboard plans are here: https://www.thingiverse.com/thing:6559930. I will keep this site more up to date than this post - so use the thingiverse site rather than this post if you plan to build it.

This is designed to be a 3D aerobatic plane. It flies well, and can perform aerobatics and 3D manoeuvres -
(maiden flight)

The plane is a combination of 3D printed parts, flite test style 5mm foamboard, and lollipop sticks.

The 3D printed parts are included as stl files (including an stl and step file of the whole plane, to help with construction).

The plans for the foamboard cutouts are included as a pdf - planeprint.pdf. It is designed for A4 paper, just print without applying any scaling and it should be accurate. you can then use this to cut out your foamboard. Some of the lines represent scores to be folded, rather than full thickness cuts. These scores include those for the:
leading edge
tab at edge of nose and tail piece

All others are full thickness cuts. The plans include servo mounting holes for the aileron servos, and control horn mounting locations. planeprintplan.pdf is a view of the entire 3x3 A4 sheets - for orientation.

The 3D printed parts will all need to be printed and assembled as shown in the stl file and photos. The fuselage is the correct orientation for printing - it has a flat bottom to help with this. Orienting the other parts is straightforward.

I used normal PLA, solid (the walls of these pieces are 1.2mm thick, so it isnt too heavy).

The hatch slides into place - slide the front piece first, then the rear piece.

The plane is designed for use with 9g servos. These mount inside the fuselage, and in the wings. There are routing holes for the pushrods in the 3D printed tailpiece.

I used a T-Motor AT2312 1150KV Fixed Wing Motor, 30A ESC and 10x4 prop. 3S 850mAH battery. My plane weighs 570g, the motor has a thrust of up to 1200g.

There is no instructional video for folding the foamboard - you will need to remove the paper from the inside of the sections to be bent, and to curl the foamboard by pressing it against a table edge. All the techniques are the same as those used in flite test foamboard planes.

I taped the foamboard once I had formed the cylinders for the nose and tail.

I used gorilla clear glue to glue all pieces in place. I also used this on the hinges, and all exposed foamboard edges, to prevent the paper from peeling.



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