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Adding payload to an RC cessna

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For just a few bucks you can add a payload to your flying toys. In this case it’s a Cessna RC plane which now has an added surprise. The first thing to be dropped was a parachute with a weight on it (for testing purposes). But there are hints of future projects that will use the same system for different purposes.

As you can see in the image above, the system depends on an additional compartment attached to the bottom of the plane. It was built from foam board to keep the weight down and connects using rare earth magnets. The bottom of the enclosure acts as the door, hinging on a servo motor with a bamboo skewer as the axle. So far the test drops have gone pretty well, but some more work needs to be done with the parachute design. It only opens about 60% of the time. We can sympathize, having had to work out some of our own parachute issues.

Don’t miss video from the plane as well as the ground after the break.


Filed under: toy hacks

Hackaday Links August 31, 2012

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Landing a fixed-wing through hotel balcony french doors

As you can see, launching an RC airplane off of a hotel balcony is easy. But watch the video and you’ll find out trying to fly through the french doors for a landing is another story. [Team BlackSheep] hits (har, har) Thailand in this collection of breathtaking flights.

Quieting rack-mount switch for home use

[VictorB] got his hands on this switch to beef up his home network. Since the three fans on the back sound like a jet engine he did some cutting to use a larger, quieter fan.

Component package alphabet

Sure, you probably know what SOIC stands for, but what is a CSP? You can clear things up a bit by studying your IC Alphabet.

ZX Spectrum audio card

For those still looking to squeeze everything they can out of a classic ZX Spectrum, here’s a way to improve the audio with a custom sound card (translated).

AVR programmer reprogrammed as an NES controller interface

[Slack] modified his USBasp programmer to uses as an NES controller interface. The hardware can be had on eBay for under $10, and he was already using one as a dev board. After seeing this USB to NES dongle post it didn’t take long to make the programmer into a gaming tool.


Filed under: news

Students build a 3D printed plane

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3d printed plane

A student team has successfully designed, built, and flown a 3D printed RC plane using only $16 of plastic with a consumer-grade 3D printer (Makerbot), plus the necessary electronics and motor.

The folks over at the Wright Brothers Institute (WBI) have a great program called the AFRL Discovery Lab which brings teams of students, businesses, researchers, and government together to work on a specific challenge or opportunity.

One of the programs this year was the Disposable Miniature Air Vehicle, or DMAV for short. The student interns [Nathan, Ben, and Brian] spent the first 5 weeks at Tec^Edge designing the plane. The team went through 5 revisions before they settled on a design they believed could fly. The final plane weighed 1.5 pounds, and on its first flight… plummeted into the ground. Good thing they printed a second copy! After some more practice [Stephen] got the hang of it and was able to fly and land the plane successfully.

According to the WBI, this is the first functional aircraft that has been fully 3D printed (sans electronics) using FDM technology, and the first low wing 3D printed plane to be flown. Hate to burst their bubble, but 3D printed quadcopters have been around for quite a while!

Test flight video is after the break.

[Thanks Geeks Anonymouse]


Filed under: 3d Printer hacks

R/C Plane Flies with a Cockpit View

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baehawkMosaic

That’s not a jet jockey making a low altitude turn up there. In fact, the pilot has his feet planted firmly on the ground. [Reliku] has built a radio controlled BAE Hawk which is flown via First Person View (FPV). FPV models often have a small camera mounted on the exterior of the craft. This camera gives a great field of view, but it isn’t exactly how full scale planes are flown.

[Reliku] took it to the next level by creating a scale cockpit for his plane. The cockpit is accurate to the real BAE Hawk T2, and features back lit simulated screens. Even the pilot got the FPV treatment. Micro servos move the pilot’s right hand in response to aileron and elevator inputs from the radio control system. The pilot’s head has been replaced with the FPV camera, which is mounted on a pan tilt unit. Pan and tilt are controlled by a head tracking system attached to [Reliku’s] video goggles. The entire experience is very immersive.

All this is built into a Hobbyking BAE Hawk Electric Ducted Fan (EDF) model, so space is at a premium. Even with the Hawk’s relatively large cockpit, [Reliku] found he was tight on space. While attempting to keep the cockpit scale from the pilot’s view, he found he was barely able to fit a single seat cockpit into a space designed for two! Adding all these modifications to a plane and still keeping the model flyable was not easy, as displayed by [Reliku’s] earlier attempt with an F-16.

The ends do justify the means though, as the final model looks great. We’d love to see those static cockpit displays replaced with small LCD or OLED panels for an even more realistic experience!


Filed under: drone hacks

Cheap, dirty and perfect V-Groove Foam Cutter

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If the only tool you have is a hammer, everything looks like a nail. Conversely, if you have the right tool for every job, it makes the difference between pro and amateur. [ftregan] needs to cut perfect V-grooves in foam for many of his projects, especially building RC planes. He wasn’t too satisfied with the results using his Xacto knife. And a proper tool was going to set him back by almost $25, but following that example he built his own version of the tool for much less.

Two pieces of wood cut at a 45 degree angle are held between two flat support pieces. A pair of regular shaving blades form the cutting elements. While it looks simple, it’s important to get the angles and blade directions correct. A central wooden wedge holds the two blades in place. He also added a small guide marker that let’s you cut precise straight grooves. [ftregan] built the tool to allow cutting 6mm thick foam but given that it’s so quick and cheap to build, we guess it’s easy to make a few of these to allow cutting different thicknesses of foam. We’re sure that many of you will find different or better ways of doing this, but considering [ftregan] spent just 15 minutes cooking this up, it’s not too bad, especially since the results are mighty good.

Another method of cutting foam is with hot wire. Check out this DIY Foam Cutter that we featured earlier.


Filed under: how-to, news

RC Plane Converted To Autogyro

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Out in the RC Airplane world, there is a great airframe called the Slow Stick. There is not much going on with this plane as it only has the bare necessities, a motor, wing, tail and a fiberglass tube (hence the ‘stick’ part of Slow Stick) as the fuselage. Yes, and as the name suggests it is slow. Although it’s intent is to be a starter plane for beginners, even experienced pilots like it because it is cheap, easy to repair and fun to modify. [StephanB] is the type of guy who likes to modify things so he set out to convert his Slow Stick to an Autogyro.

An Autogyro can be described as a cross between a plane and a helicopter. Like a plane it has a propeller that provides forward thrust. Unlike a plane, it does not have a wing. To provide lift, there is a large helicopter-like rotor on top of the craft but this rotor is not powered. It only spins when the craft is moving forward. Lift is created when the rotor is spinning, allowing the Autogyro to take off.

[StephanB] started by removing his Slow Stick’s wing. This takes all of 2 seconds and consists of only removing 2 rubber bands. Next he built a frame for the rotor. It was made to fit the wing mounts of the Slow Stick so that it could be quickly converted back to a plane. With a spinning Autogyro rotor, the side that the rotor is traveling in the forward direction creates more lift than the side of the rotor traveling rearward. To compensate for this unequal lift, [StephanB] added a sideways tilting rotor mount. An RC servo is connected to the mount and allows remote control of the rotor to balance out the lift.

Slow Stick Auto Gyro


Filed under: toy hacks

Move Over Red Bull, Hot Wire Foam Cutter Now Gives You Wings

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Not many people will argue with flying RC airplanes is super fun. One big bummer is when a crash damages a part beyond repair. Sure, the RC pilot could keep buying replacement parts but doing so will add up after a while. RC plane builder and general guy with a cool name, [HuckinChikn], decided to build a hot wire foam cutter so making replacement wings would be quick and cheap.

The actual hot wire part is nothing special, just some wire pulled taut across a frame and a 24 vdc power supply pumping out current and heating the wire so it melts any foam in its path. The unique part of the build is that one side of the hot wire frame is secured in place and only allowed to pivot about that point. The other side of the frame traces an airfoil-shaped pattern. This setup allows [HuckinChikn] to make tapered wings. The difference between a straight wing and a tapered wing is similar to that of a cylinder and cone.

hotwire foam wing cutter

Check out the video after the break for a quick demonstration how easy it is to make a wing when you have the right tool!


Filed under: tool hacks

3D Printed Plane Flies High

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One of our avid readers, [Niklas Melton] loves RC planes. After getting into 3D printing, the next logical step was to start building is own planes… And now he’s done it!

He calls it the Air-Form 1 Micro RC plane, paying homage to the FormLabs resin printer he used. All of the parts except for the electronics were printed using a tough resin. It’s designed to take balsa wood wings into clips he designed into the parts. A 150mAh battery provides the power with a motor that exerts about 54g of thrust — not bad considering the entire thing only weighs 60g! Unfortunately he doesn’t have any video clips of it flying, though he assures us it does indeed fly — if you’re interested in building your own, he’s uploaded all the files to a page on Thingiverse.

As more advanced 3D printers come down in price, like the SLA technology, it becomes possible to design and 3D print even more complex parts. Some of the resins available have now some pretty amazing properties. One of our readers replaced a servo spline gear with one he printed — which works even better than the original!


Filed under: 3d Printer hacks, radio hacks

Flying Planes With Squirrel Cages

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Fixed wing remote control planes are ridiculously overpowered. Whereas normal, manned fixed wing aircraft need to take into account things like density altitude, angle of attack, and weight limits, most RC aircraft can hover. This insane amount of power means there’s a lot of room for experimentation, especially in new and novel power plants. [Samm Sheperd] had an old squirrel cage fan taken from an electric wall heater and figured one man’s trash was an integral part of another man’s hobby and built a plane around this very unusual fan.

squirrel-cage-fan-wideThe only part of the squirrel cage fan [Samm] reused was the impeller. Every other part of this power plant was either constructed out of foam board, plywood, or in the case of the brushless motor turning the fan, stolen from the ubiquitous box of junk on every modeller’s workbench.

The design of the plane puts the blower fan directly under the wings, blasting the air backwards underneath the empennage. During testing, [Samm] found this blower pulled around 350W from the battery – exactly what it should draw if a properly sized propeller were attached to the motor. The thrust produced isn’t that great — only about 400g of thrust from an airframe that weights 863g. That’s very underpowered for an RC aircraft, but absurdly powerful for any manned flying machine.

Does the plane work? Of course it does. [Samm] took his plane for a few laps around the neighborhood and found the plane flies excellently. It is horrifically loud, but it is a great example of how much anyone can do with cheap RC planes constructed out of foam.


Filed under: drone hacks

KFC Winged Aircraft Actually Flies

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[PeterSripol] has made an RC model airplane but instead of using normal wings he decided to try getting it to fly  using some KFC chicken buckets instead. Two KFC buckets in the place of wings were attached to a motor which spins the buckets up to speed. With a little help from the Magnus effect this creates lift.

Many different configurations were tried to get this contraption off the ground. They eventually settled on a dual prop setup, each spinning counter to each other for forward momentum. This helped to negate the gyroscopic effect of the spinning buckets producing the lift. After many failed build-then-fly attempts they finally got it in the air. It works, albeit not to well, but it did fly and was controllable. Perhaps with a few more adjustments and a bit of trial and error someone could build a really unique RC plane using this concept.


Filed under: drone hacks, transportation hacks

3D Printed Ribs For Not 3D Printed Planes

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A few months ago, [Tom] built a few RC planes. The first was completely 3D printed, but the resulting print — and plane — came in a bit overweight, making it a terrible plane. The second plane was a VTOL tilt rotor, using aluminum box section for the wing spar. This plane was a lot of fun to fly, but again, a bit overweight and the airfoil was never quite right.

Obviously, there are improvements to be made in the field of 3D printed aeronautics, and [Tom]’s recent experiments with 3D printed ribs hit it out of the park.

If you’re unfamiliar, a wing spar is a very long member that goes from wingtip to wingtip, or from the fuselage to each wingtip, and effectively supports the entire weight of the plane. The ribs run perpendicular to the spar and provide support for the wing covering, whether it’s aluminum, foam board, or monokote.

For this build, [Tom] is relying on the old standby, a square piece of balsa. The ribs, though, are 3D printed. They’re basically a single-wall vase in the shape of a wing rib, and are attached to the covering (foam board) with Gorilla glue.

Did the 3D printed ribs work? Yes, of course, you can strap a motor to a toaster and get it to fly. What’s interesting here is how good the resulting wing looked. It’s not quite up to the quality of fancy fiberglass wings, but it’s on par with any other foam board construction.

The takeaway, though, is how much lighter this construction was when compared to the completely 3D printed plane. With similar electronics, the plane with the 3D printed ribs weighed in at 312 grams. The completely 3D printed plane was a hefty 468 grams. That’s a lot of weight saved, and that translates into more flying time.

You can check out the build video below.


Filed under: 3d Printer hacks

A Remote Controlled Air-Plane

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The Air Hogs Sky Shark was a free-flying model airplane powered by compressed air. When it was released in the late ’90s, it was a fairly innovative toy featuring a strikingly novel compressed air engine made entirely out of injection molded plastic. Sales of these model planes took off, and landed on the neighbor’s roof, never to be seen again.

A few weeks ago, [Tom Stanton] revisited this novel little air-powered motor by creating his own 3D printed copy. Yes, it worked, and yes, it’s a very impressive 3D print. That build was just on a workbench, though, and to really test this air motor out, [Tom] used it to propel a remote-controlled plane through the air.

The motor used for this experiment is slightly modified from [Tom]’s original air-powered motor. The original motor used a standard 3-blade quadcopter prop, but the flightworthy build is using a much larger prop that swings a lot more air. This, with the addition of a new spring in the motor and a much larger air tank constructed out of plastic bottles results in a motor that’s not very heavy but can still swing a prop for tens of seconds. It’s not much, but it’s something.

The airframe for this experiment was constructed using [Tom]’s 3D printed wing ribs, a carbon fiber boom for the tail, and only rudder and elevator controls. After figuring out some CG issues — the motor doesn’t weigh much, and planes usually have big batteries in the nose — the plane flew remarkably well, albeit for a short amount of time.

 

3D Printed Upgrade for Cheap Foam Glider

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We know you’ve seen them: the big foam gliders that are a summertime staple of seemingly every big box retailer and dollar store in the world. They may be made by different companies or have slight cosmetic differences, but they all adhere to the basic formula: a long plastic bag containing the single-piece fuselage and two removable wings and a tail. Rip open the bag, jam the wings into the fuselage, and go see if you can’t get that thing stuck on a roof someplace.

But after you toss it around a few times, things start to get a little stale. Those of us in the Hackaday Collective who still retain memories of our childhood may even recall attempting to augment the glider with some strategically attached bottle rockets. But [Timothy Wright] has done considerably better than that. With the addition of a 3D printed “backpack”, he managed to add not only a motor to one of these foam fliers but an RC receiver and servos to move the control surfaces. The end result is a cheap and surprisingly capable RC plane with relatively little work required.

[Timothy] certainly isn’t claiming to be the first person to slap a motor on a foam glider to wring a bit more fun out of it, but his approach is very slick and of course has the added bonus of being available for other grownup kids to try thanks to the Creative Commons license he released the designs under. He mentions that variations in the different gliders might cause some compatibility issues, but with the generous application of some zip ties and tape, it should be good to go.

This particular hunk of foam might not set any altitude or distance records, and it certainly won’t be carrying you aloft, but it’s a pretty approachable summer project if you’ve got some RC gear laying around.

Cheap RC Boat Turned Weirdly Capable Seaplane

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What do you get when you combine a cheap RC boat from Walmart, foam board, a couple powerful motors, and some aluminum cans? Most people would just end up with a pile of garbage, but we’ve already established [Peter Sripol] is fairly far from “most people”. In his hands, this collection of scraps turns into an almost unbelievably nimble seaplane, despite looking like something out of a TailSpin and Mad Max crossover episode.

In his latest YouTube video, [Peter] takes viewers through the process of turning one of these rather lame RC boats into an impressive flying machine. His took inspiration from the Sikorsky S-38, an American amphibious aircraft introduced in 1928. The S-38 looked like a fairly traditional boat bolted to the bottom of a set of huge wings, so it’s little surprise that he patterned this build after it.

The construction of the seaplane is very simple, and boils down to cutting some big wings out of foam board, using some sticks to give it some rigid framing, and putting a tail on it. The biggest problem is that the boat’s hull lacks the “steps” that a seaplane would have, so it’s not an ideal shape to lift out of the water. But with enough thrust and a big enough control surface, it all works out in the end.

Which is in effect the principle by which the whole plane flies. There’s a large elevator cantilevered far astern to help leverage the boat out of the water, but otherwise all other control is provided by differential thrust between the two top mounted motors. The lack of a rudder does make its handling a bit sluggish in the water, but it obviously has no problem once it’s airborne.

If [Peter] and his foam board artistry seem familiar, it’s probably from the not one but two homemade aircraft he built with shockingly similar techniques to this current project.

Awesome Looking 3D Printed RC Plane Is Full Of Design Considerations

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Designing and 3D printing RC planes offer several interesting challenges, and so besides being awesome looking and a fast flier, [localfiend’s] Northern Pike build is definitely worth a look. Some details can be found by wading through this forum but there’s also quite a bit on his Thingiverse page.

Tongue-and-groove joint for the wing
Tongue-and-groove joint

Naturally, for an RC plane, weight is an issue. When’s the last time you used 0% infill, as he does for some parts? Those parts also have only one perimeter, making this thin-walled-construction indeed. He’s even cut out circles on the spars inside the wings. For extra strength, a cheap carbon fiber arrow from Walmart serves as a spar in the main wing section. Adding more strength yet, most parts go together with tongue-and-groove assembly, making for a stronger join than there would be otherwise. This slotted join also acts as a spar where it’s done for two wing sections. To handle higher temperatures, he recommends PETG, ABS, ASA, Polycarbonate, and nylon for the motor mount and firewall while the rest of the plane can be printed with PLA.

As you can tell from the videos below, [localfiend’s] flier is a high-performance 3D printed machine. But such machines don’t have to be relegated to the air as this RC jet boat demonstrates. Though some do hover on a thin cushion of air.

When launching his first flight, he learned that he didn’t need to toss it too hard.

We’re grateful to [Aidan] for sending in this tip.


How To Slice Lightweight Aircraft Parts For 3D Printing

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Historically, remote control aircraft were produced much like their early full-sized counterparts. Wooden structures were covered with adhesives and taut fabric membranes. Other techniques later came to the fore, with builders looking to foam and other materials. Of course, these days 3D printers are all the rage, so perhaps one can simply print out a whole plane? As [sahevaantaneja] discovered, it’s not that easy!

One of the foremost problems is the process of slicing. This is where 3D geometry is transformed into the G-code which defines the path taken by the 3D printer during production of a component. Slicer software is generally optimised for working with mostly-solid objects, and some tweaks can be required when working with thin-walled designs.

These challenges come to bear with an aircraft design, which, by necessity must be lightweight. [sahevaantaneja] does a great job of explaining the journey of discovery in which their design was optimised to work with conventional slicers. This allowed the various components to be printed without errors, while retaining their strength to survive in flight.

The design was successful in test flights –  a great reward after much experimentation. We’ve seen other 3D printed designs take flight, too. Video after the break.

VTOL Tailsitter Flies With Quadcopter Control Software

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Quadcopters are great for maneuverability and slow, stable flight, but it comes at the cost of efficiency. [Peter Ryseck]’s Mini QBIT quadrotor biplane brings in some of the efficiency of fixed-wing flight, without all the complexity usually associated with VTOL aircraft.

The Mini QBIT is just a 3″ mini quadcopter with a pair of wings mounted below the motors, turning it into a “tailsitter” VTOL aircraft. The wings and nosecone attach to the 3D printed frame using magnets, which allows them to pop off in a crash. There is no need for control surfaces on the wings since all the required control is done by the motors. The QBIT is based on a research project [Peter] was involved in at the University of Maryland. The 2017 paper states that the test aircraft used 68% less power in forward flight than hovering.

(Editor’s Note: [Peter] contacted us directly, and he’s got a newer paper about the aircraft.)

Getting the flight controller to do smooth transitions from hover to forward flight can be quite tricky, but the QBIT does this using a normal quadcopter flight controller running Betaflight. The quadcopter hovers in self-leveling mode (angle mode) and switches to acro mode for forward flight. However, as the drone pitches over for forward flight, the roll axis becomes the yaw axis and the yaw axis becomes the reversed roll axis. To compensate for this, the controller set up to swap these two channels at the flip of a switch. For FPV flying, the QBIT uses two cameras for the two different modes, each with its own on-screen display (OSD). The flight controller is configured to use the same mode switch to change the camera feed and OSD.

[Peter] is selling the parts and STL files for V2 on his website, but you can download the V1 files for free. However, the control setup is really the defining feature of this project, and can be implemented by anyone on their own builds.

For another simple VTOL project, check out [Nicholas Rehm]’s F-35 which runs on his dRehmFlight flight control software.

 

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