3D printed tricopter - from CAD to reality! - Blogs

Hi,

I'm Adrian from Hungary/Europe. Let me introduce my tricopter project.

My goal was to make something really good-looking copter that have ally features I need.The design process started 1 years ago. My first idea was to make a composite chasis, from glass/carbon fiber.I designed the copter in a 3D modelling software, and also designed the necessary moulds for making each parts, here is the initial design:

This is a sample of the mould design:

I also made some FEM calculations, to check the stress dispersion:

Unfortunatelly, this type of production would cost too much for me. I tried to find partners in Hungary, without success. So I almost forgot this project. But some months before I read a lot about 3D printing, and finally I found a great partner in Hungary (many thanks to the Ground Zero Team www.groundzero.hu !!!). So I started to redesign my copter according to the requirements of 3D printing:

Then I sent the .stl files for FDM printing. Here is the result:

This is my current configuration:

Turnigy SK3-2826-1130 motors
8x4,5 karbon SF props
10A HK ESC (simonK firmware)
ArduFlyer 2.5 with ArduCopter 3.0.1 code
ULOX NEO6-M GPS
2000mA 3S lipo (2 db 1000mA 3S2P)
Flytron 25A ultralight current sensor
MKS-DS95 servo
RECOM 5V 1A power supply for electronics
3DR 868 MHz telemetry module
RCTimer OLED screen
Immersion 600mW 5.8 video TX + Coverleaf antenna
MinimOSD, with KVTeam code
KPC-E700PUB camera
FRSKY Futaba FASST-compatible receiver, PPM
controlled LED-s and buzzer

All-up weight is 782g, and has 8 minutes of safe flight time with 20-25% of remaining battery.

(Please note that I used Crius AIO Pro at first with MWI code and KV-OSD code. These can be found on the following pictures and in the videos.)

LED sripes are controlled by APM:

Here are some videos:

Flight test (with Multiwii)

Onboard video (with Multiwii + KV-OSD)

For more details please connect me by mail: nhadrian@gmail.com

- UPDATE -

stl files can be downloaded from here:

http://shpws.me/oGJN
http://shpws.me/oGKc
http://shpws.me/oGKd
http://shpws.me/oGKg
http://shpws.me/oGK7

And these are the additional metal parts for rear arm control:

I wish you all good luck on reproducing my tri.

Please note that I'll not modify desing according to personal wishes, since my spare time is quite limited and I focus on my personal projects. Thanks for understanding!!!

Best Regards

Adrian

FDM is the technoligy itself (Fused Deposition Modeling), developed by Stratasys.

http://en.wikipedia.org/wiki/Fused_deposition_modeling

The model material is ABS, the weight calculated in the CAD system is the same as the real one.

This technology can give high strength, but is anisotropic and the surface quality is not as smooth as for STL printing (Selective Laser Sintering). If you can access the printing software too (CatalystEX), you can check your parts layer by layer. It is sometimes important if you have difficult shapes.

The maximum size of parts are 200x200x200 mm, and can be closed too, since FDM printers using another material wire for supports, which can be solved after.

Aynway, I used wall thicknesses of 1.8 to 3 mm, depending on the stresses in the parts (I'm a mechanical engineer and learnt a lot of FEM (finite element method)). And also I used some ribs for problematic points.

Another advantage of FDM printing is that ABS parts can be machined too, so it is easy to drill holes, etc.

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Comments

Adrián Nagy Hinst September 8, 2013 at 10:51pm

Roberto, could you contact me by mail?

Best Regards

Adrian
Adrián Nagy Hinst September 8, 2013 at 10:40pm

For stl files, please connect me by mail.
Adrián Nagy Hinst September 8, 2013 at 10:34pm

FDM is the technoligy itself (Fused Deposition Modeling), developed by Stratasys.

http://en.wikipedia.org/wiki/Fused_deposition_modeling

The model material is ABS, the weight calculated in the CAD system is the same as the real one.

This technology can give high strength, but is anisotropic and the surface quality is not as smooth as for STL printing (Selective Laser Sintering). If you can access the printing software too (CatalystEX), you can check your parts layer by layer. It is sometimes important if you have difficult shapes.

The maximum size of parts are 200x200x200 mm, and can be closed too, since FDM printers using another material wire for supports, which can be solved after.

Aynway, I used wall thicknesses of 1.8 to 3 mm, depending on the stresses in the parts (I'm a mechanical engineer and learnt a lot of FEM (finite element method)). And also I used some ribs for problematic points.

Another advantage of FDM printing is that ABS parts can be machined too, so it is easy to drill holes, etc.
Moderator

Gary Mortimer September 8, 2013 at 10:29pm

Very nice, well done
Earl September 8, 2013 at 10:27pm

Are you going to make the STL files available? That would be super.

Earl
Moderator

Roberto Navoni September 8, 2013 at 10:08pm

Here you can see our process that is the same of your ;)

During this two year of test we found shapeways as good partner for our prototype. Sometimes produce wrong part , but at the end the result is good . The other problem is that the specification of material that we found on shapeways website is a lot different of what is the real result , so fdm in the cad is different of real part.

What material are you used and what fast prototype service ? How minimum thickness are you drone ?

Best

Roberto
Adrián Nagy Hinst September 8, 2013 at 9:54pm

Hi Roberto, for me FDM printing is more than enough. I can calculate the weak points of this technology, and ABS material can be easilly repaired with various types of glues.

Also I can check printing on PC layer by layer and modify the 3D model if necessary.

I don't want to make product, I don't have time and money for that.

So my oppinion is that 3D printing (especially FDM one) is great for prototype production, if designer knows the weakness of technology and can calculate during desing process!
Moderator

Roberto Navoni September 8, 2013 at 9:46pm

Great Job Adrian,

we have your same problem , developed a good design with fast prototyping , but the price of molding is very high.

If you try to search company in china you can obtain price 1/5 respect of Europe.

best

Roberto
Adrián Nagy Hinst September 8, 2013 at 9:36pm

Hi, I know FDM printed parts are highly anisotropic.

It has strongly grain directions, I take into consideration that when designed the reinforcement ribs.

And also I defined the printing orientations for each parts, to have the best strength.

Please note that this is a prototype, not a final product! Although since finished, I had small crashes from 1-1,5m during setting up AC3.0.1, but without any damage in frame (only broken props).

I still have my oppininon that composite hull structure would be better.

BR

Adrian
Keith Callaghan September 8, 2013 at 9:14pm

Have seen others try to make parts that should be moulded by using 3D printing instead. Be aware, I think you will find the 3D parts fracture quite easily compared to moulded.

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