Aluminium Arducopter parts - first attempt!

As part of my plane to create a simple, solid Arducopter frame, I have had a number of parts laser cut in 2mm 6082 aluminium from the original Arducopter frame design by the DIYD team.



The parts have come back a little more "bashed up" than I expected, but apparently that's normal, they just need a clean-up with something abbrasive.


I had trouble opening the DXF files in the SVN. In the end I opened them in Microsoft Visio, saved them as Autocad files and then exported them back into DXF files from within Autocad after I tweaked the legs etc not to need the dome. The laser cutters seemed to need the DXF files in the 2004 format attached.


I can't verify anything fits (they've just arrived and I'm in the office), but for those feeling brave the DXF files I used are attached for anyone that wants them.










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Comment by Alex on May 13, 2011 at 4:56am

Hey thats pretty cool, I would like to know where you had them made?  Was it in the UK?  


Also usefull that you shared the DFX files because I too had trouble opening them from SVN a few months ago..


Anyways looking forward to the build pics and weight at the end of it

Comment by DaveyWaveyBunsenBurner on May 13, 2011 at 4:59am

Hi Alex,


Hope they prove useful to you. Yes I had them cut in the UK by a company called cut-tec. Protyping has been very expensive (most of the cost is in setup), but a run of ten sets or so dramatically reduces the price. The way I fly I need plenty of spares :)


I'll keep you all posted...


Comment by Ethan Ferrell on May 13, 2011 at 6:19am
Looking good. Do you plan to use any plastic or nylon hardware? Maybe metal screws with plastic spacers? How is it as far as weight? I used 2mm and 3mm Delrin plastic for my build (blog post coming soon) and it might be as heavy as yours :P.
Comment by DaveyWaveyBunsenBurner on May 13, 2011 at 6:25am


I still have my Arducopter kit sitting at home ready for a build (hopefully this weekend) so I was going to have a sit down and use the plastic kit screws for now and then upgrade to aluminium if/as required. Spacers etc will be plastic and I may need to insulate the carrier boards for obvious reasons.


Weight wise I have no idea! When I get her anywhere near finished I will throw her on the scales! I have the original parts for comparison.

Comment by DaveyWaveyBunsenBurner on May 13, 2011 at 6:55am


I ran down to the post room and weighed one set consisting of: 2 main boards, 1 carrier, 4 motor upperas, 4 motor lowers, 1 batter holder, 8 legs and the total was 212 grams. I have nothing to compare that to until I get home...

Comment by Ethan Ferrell on May 13, 2011 at 7:05am
Doesn't sound too bad. I still need to weigh my Delrin and compare to your numbers. Would be beneficial for the community to get weight measurements for each type of material. Mine wouldn't be comparable though because I enlarged my main plate and carrier boards for the Chumby.

I was thinking about the plastic screws: one benefit would be that they would hopefully break and relieve pressure before any of the metal bends. But then, they may break too often and the aluminum remains well under it's bending point.

Comment by Gary Mortimer on May 13, 2011 at 7:07am
Thanks for those DXFs Dave I might cut some in G10 and see how they go.
Comment by Ken McEwan on May 13, 2011 at 7:08am
Excellent! I just wish the decision was made to go with aluminum when I was on the arducopter frame development team. I had a couple of aluminum prototypes made here in the US that turned out very good. Two sets were powder coated and one was anodized.
Comment by Ethan Ferrell on May 13, 2011 at 7:19am
Doing a powder coat would look sick...Do you know the cost of that?
Comment by Russell B. Sutton on May 13, 2011 at 7:20am

What is the weight of your all Aluminum Copter skeleton.  I'm working on a Foam and Carbon arrow shaft frame.  Should be about 175 grams. 


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