Dear all,
I am very much interested to make composite UAVs. I tried many ways for making it like foam core, wooden patterns, prepreg etc. And I am here to have a discussion on making the plug and material selection for rugged design for deep-stall landings. Please anyone interested suggest something for my query.
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So what are you asking?
We use either composite molds or molds machined from tooling foam. The tooling foam is relatively cheap compared to aluminum or carbon fiber but, the foam has a bit higher CTE. The last uav mold I made was from this foam and worked pretty well except that my design was so so. I'm currently trying to design a new air frame and I'd like to implement 3d printed molds and mandrels. Ultimately my plan is to have a 'moldless' air frame chassis that I can easily replicate.
Where are you now on the design?