I've been experimenting to find a strong "tubular" profile that could be printed reliably. The angled sections in these designs are 35 degrees to vertical - so well within the typical 45 degree capability of most printers. They arms only present about 11mm of flat surface to minimize obstruction to airflow.
The rest of the design are a collection of ideas that have accumulated over the past year building various quadcopters and Y6 configurations (3D printed, aluminium and bought frames).
- completely 3D printable (without support)
- simple assembly
- coaxial design (2 motors per arm) provides redundancy to keep flying in case of an ESC, motor, or prop failure
- strong braced tube section arms with plenty of room to conceal motor wiring
- designed for dual (3S) batteries located right in the center of rotation/thrust with room for up to 2 x 6000mah batteries (although 3000mah and some foam padding might be a wiser option)
- easy cable routing with beveled cable "tunnels" (and even a few cable tie mounts)
- plenty of space to mount ESCs - concealed but still well ventilated for cooling
- top plate is designed for a Pixhawk - but can easily be tweaked for others
- RF "invisible" frame - as opposed to carbon fiber or aluminium
- Frame weight is approx 300g. All up weight including 2 x 3S 3000mah batteries and my over-sized 880kv motors is 1,700g.
- Sketchup file included so you can make changes to suit yourself
I'm hoping to get some design inspiration to make the body a bit less "boxy" - while still keeping it printable.