Replies to This Discussion

Permalink Reply by Ellison Chan on November 26, 2012 at 1:48pm

I use a combination of Blender and FreeCad to design and then print my parts on a Makerbot TOM.
Blender is good for assembling things, and punching holes and such in meshes, and I use FreeCad for precise drafting work, and export the meshes for blender to use.

Recently, I've discovered OpenScad, to build geometric objects programmatically, like gears.

Here's a recent HexaCopter, I've been working on:

http://diydrones.com/group/3d-printing-drone-parts/forum/topics/my-...

Permalink Reply by Harry on November 27, 2012 at 10:01am

I submitted that rib shape to shapeways just to see what they would charge.  What a ripoff.  They wanted $32.00 for it and didnt even have a way for me to verify dimensions. 

My plan was to print some ribs and then fill with 2 part foam, sand to shape and cover with fiberglass.  It looks like it's back to kinkos and a copy machine as my wing building method.

Permalink Reply by Ellison Chan on November 27, 2012 at 10:24am

Yeah, I printed a couple copters using Shapeways. It is very expensive.
Btw, to make the wing section, you need to extrude it so that it has thickness. Then you can use the "array" operation on it to make as many sections as you need for the wing. If you use an "object offset" relative to an empty that scales in the direction of the run, you can even create a taper. Then a boolean operation on the spar to create a slot.

It's actually easier to do than describe. Send me you wind section file, and I can make an example for you to play with.

Permalink Reply by Harry on November 27, 2012 at 11:37am

Ok, thanks.  Here's a shot of the latest.  I cleaned up the leading edge.

Attachments:

• 7408.blend, 349 KB

Permalink Reply by John Whetten on December 1, 2012 at 10:46pm

I am a fairly experienced Blender user, and I have been trying to design and print a plane that is 3D printed, but shapeways keeps rejecting my models based on wall thinness. As it turns out, the thickness requirements are much more complicated than what are posted on their website. Anyway, it would be fun if I can get it to work. It is expensive, but it would be an interesting proof-of-concept.

Here is a quick render of a wing section that is designed to fit over a carbon fiber tube spar. I would like to integrate ailerons and flaps into the design, and so there is also an image showing a design exercise of trying to achieve this. (Please ignore geometry problems)

If there is someone out there who is interested in a project like this, please let me know as it would be helpful to team up on something this complex.

Attachments:

• WingSection.png, 283 KB
• AileronFlapSection.png, 235 KB

Permalink Reply by Ellison Chan on December 2, 2012 at 9:07am

Yeah, I tried too on Shapeways.  Basically, the problem is that with the air foil shape the trailing edge always gets to thin for them. If you attach the stl or blender files, I can attempt a print on the TOM.  The Replicator software is much more forgiving with thin walls.

Permalink Reply by Harry on December 2, 2012 at 7:09pm

Yeah, that's beautiful.  I submitted a wing tip that was just a mesh converted from the beziers and they didnt have a problem with it.  I saw the price and started boring holes in it by removing faces.  When I submitted that, they rejected it.  I then went back and used the solify modifier and they liked it.  The price dropped 90%.

Permalink Reply by Ellison Chan on December 2, 2012 at 9:11pm

On Shapeways, hollow objects are cheaper, of course.  Also, the larger the object the lower per volume price is, up to a point.

Permalink Reply by Harry on December 2, 2012 at 9:43pm

I called their bluff to see if they will actually print my design.  My plan at this point is use it to make a mold since I expect it would be too fragile to fly.  I'll fill it and then give it an epoxy skin for molding.  Molds arent cheap either, but I need it to complete my design and go with the pod mold I already have. 

Permalink Reply by Ellison Chan on November 27, 2012 at 12:40pm

I need the file with the Nurbs curve not the mesh.

Permalink Reply by Harry on November 27, 2012 at 6:17pm

Oops, maybe this will help.  I attached the background image in case you need it.  Also, it's actually 2 nurbs curves, one for the top and one for the bottom of the foil.

Attachments:

• NACA7408.xcf, 46 KB
• NACA7408.blend, 343 KB

Permalink Reply by Ellison Chan on November 27, 2012 at 8:57pm

Here's the file with the extruded wing:

http://api.ning.com/files/YKx5URazVtf35dEJ2kdACfB5G4-tYdra2UBuS*GLKbiK4d-cWDm*FDOI7400FMgAVGNYM8NNCK-dEF9iNU2Z6g__/wingextrude.blend

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