Designing and Printing a High-Flying 3D Airplane: The PiperPrint Project

Still a work in progress.    

     Introducing PiperPrint, a fully functional, remote-controlled airplane that balances form and function while pushing the limits of what is possible with 3D printing. 

Notable Features: 

1. Proper aerodynamic design. From wing choice (NACA 4412) to fine-tuning of centre-of-gravity, this aircraft is designed to have innate stability and be easy for beginners.
2. Compatibility with off the shelf parts: Standard sizes are used for the motor, servos and battery compartment. Specifics provided below.
3. Detachable wings. Wings and fuselage are not permanently attached allowing for easier transport/storage. Also, If a wing or fuselage is damaged in flight you don't have to replace the whole aircraft.
4. Replaceable landing gear. The landing gear take quite a beating during take-off and landing. Being able to replace the gear separately saves a lot of waste.
5. Filament hinges for control surfaces. These hinges allow for easy removal of control surfaces even after full assembly.

Video 1  & Video 2   *Waiting for suitable winds to record a flight video.

     Airplane is compatible with regular wheels. Due to snow in my area aircraft will be flown with skis until later in the spring.

Parts Compatibility:

Motor:  ~1400KV 7-9" prop. Uses standard 34mm motor mount. Link

Servos: 4x SG90/MG90 servos. Will likely need to extend cable on both aileron servos. Link

Battery: 22x35x110mm 2200mAh 3S battery used for testing. Support up to 40x120x26mm. (Amazon link dead)

ESC: Any standard RC aircraft ESC should work. Needs to fit in lower compartment of Body1. Approx. max size: 20X45X160mm. Link

Wing Spar (Optional): .210in OD. Two sections approx 330mm each.

Required for assembly:

Superglue.

Screws: 12 M2x10, 6 M2x16, and 2 M2x20 

Sandpaper: 220, 400, and 600 grit

Printing Instructions:

     This aircraft consists of 32 separate printable parts. This section will outline the number of each part needed as well as some instructions for slicing. All parts can be printed in either PLA or PETG. *Note: Certain information such as Print Speed will not be provided as these values vary from printer to printer.

1. Nosecone - 1x 
   Walls: 2
   Infill: 25%  (Cubic Sub)
   Top : 5
   Bottom : 5
   Build plate adhesion : Brim  
2. Body1 - 1x
   Walls: 2
   Infill: 25%  (Cubic Sub)
   Top : 5
   Bottom : 5
   Build plate adhesion : Brim    
3. Body2 - 1x 
   Walls: 2
   Infill: 50%  (Cubic Sub)
   Top : 5
   Bottom : 5
   Build plate adhesion : Brim    
4. Body3 - 1x
   Walls: 2
   Infill: 25%  (Cubic Sub)
   Top : 5
   Bottom : 5
   Build plate adhesion : Brim    
5. Tail - 1x
   Walls: 2
   Infill: 30%  (Cubic Sub)
   Top : 5
   Bottom : 5
   Build plate adhesion : Brim    
6. HorizontalStab - 1x
   Walls: 3
   Infill: 15%  (Cubic Sub)
   Top : 2
   Bottom : 1
   Build plate adhesion : Skirt/None
7. Elevator - 1x
   Walls: 4
   Infill: 15%  (Cubic Sub)
   Top : 2
   Bottom : 1
   Build plate adhesion : Skirt/None
8. Rudder - 1x
   Walls: 4
   Infill: 10%  (Cubic Sub)
   Top : 2
   Bottom : 1
   Build plate adhesion : Skirt/None
9. RightStart - 1x
   Walls: 1
   Infill: 3%  (Cubic Sub)
   Top : 6
   Bottom : 6
   Build plate adhesion : Brim
10. RightMiddle - 1x
    Walls: 1
    Infill: 3%  (Cubic Sub)
    Top : 6
    Bottom : 6
    Build plate adhesion : Brim
11. RightEnd - 1x
    Walls: 1
    Infill: 3%  (Cubic Sub)
    Top : 6
    Bottom : 6
    Build plate adhesion : Brim
12. RightCap - 1x
    Walls: 1
    Infill: 3%  (Cubic Sub)
    Top : 5
    Bottom : 6
    Build plate adhesion : Brim
13. RightAileron - 1x
    Walls: 1
    Infill: 5%  (Cubic Sub)
    Top : 6
    Bottom : 6
    Build plate adhesion : Brim (XL)
14. LeftStart - 1x
    Walls: 1
    Infill: 3%  (Cubic Sub)
    Top : 6
    Bottom : 6
    Build plate adhesion : Brim
15. LeftMiddle - 1x
    Walls: 1
    Infill: 3%  (Cubic Sub)
    Top : 6
    Bottom : 6
    Build plate adhesion : Brim
16. LeftEnd - 1x
    Walls: 1
    Infill: 3%  (Cubic Sub)
    Top : 6
    Bottom : 6
    Build plate adhesion : Brim
17. LeftCap - 1x
    Walls: 1
    Infill: 3%  (Cubic Sub)
    Top : 5
    Bottom : 6
    Build plate adhesion : Brim
18. LeftAileron - 1x
    Walls: 1
    Infill: 5%  (Cubic Sub)
    Top : 6
    Bottom : 6
    Build plate adhesion : Brim (XL)
19. Gear - 1x
    Walls: 3
    Infill: 15%  (Cubic Sub)
    Top : 6
    Bottom : 6
    Build plate adhesion : Brim
20. RightSki - 1x
    Walls: 2
    Infill: 25%  (Cubic Sub)
    Top : 6
    Bottom : 6
    Build plate adhesion : Brim
21. LeftSki - 1x
    Walls: 2
    Infill: 25%  (Cubic Sub)
    Top : 6
    Bottom : 6
    Build plate adhesion : Brim
22. RearGear - 1x
    Walls: 3
    Infill: 10%  (Cubic Sub)
    Top : 6
    Bottom : 6
    Build plate adhesion : Brim
23. RearSki - 1x
    Walls: 2
    Infill: 25%  (Cubic Sub)
    Top : 6
    Bottom : 6
    Build plate adhesion : Brim
24. BodyMount - 1x
    Walls: 5
    Infill: 50%  (Cubic Sub)
    Top : 6
    Bottom : 6
    Build plate adhesion : Brim/Skirt/None
25. SparMount - 1x
    Walls: 5
    Infill: 50%  (Cubic Sub)
    Top : 6
    Bottom : 6
    Build plate adhesion : Brim/Skirt/None
26. BatteryRetainer - 1x
    Walls: 1
    Infill: 15%  (Cubic Sub)
    Top : 5
    Bottom : 5
    Build plate adhesion : Skirt/None
27. ServoCover - 1x
    Walls: 1
    Infill: 5%  (Cubic Sub)
    Top : 5
    Bottom : 5
    Build plate adhesion : Brim
28. WingJoiner - 12x
    Walls: 3
    Infill: 5%  (Cubic Sub)
    Top : 5
    Bottom : 5
    Build plate adhesion : Brim
29. Body1&2_Joiner - 3x
    Walls: 3
    Infill: 20%  (Cubic Sub)
    Top : 5
    Bottom : 5
    Build plate adhesion : Skirt
30. Body2&3_Joiner - 3x
    Walls: 3
    Infill: 20%  (Cubic Sub)
    Top : 5
    Bottom : 5
    Build plate adhesion : Skirt
31. Body3&Tail_Joiner - 3x
    Walls: 3
    Infill: 20%  (Cubic Sub)
    Top : 5
    Bottom : 5
    Build plate adhesion : Skirt
32. ServoStrap - 2x
    Walls: 3
    Infill: 10%  (Cubic Sub)
    Top : 5
    Bottom : 5
    Build plate adhesion : Skirt

Assembly Instructions:

     The fuselage sections should be glued together using their appropriate connectors. For example, Body1 and Body2 are joined using 3 Body1&2_Joiners. 

     Wing assembly Is similar. First, wing joiners should be glued into the small holes on the end of each wing section, then wings are glued together using the joiners as guides.

     Control surfaces are attached using PLA/PETG hinges. Simply line up each control surface an insert 1.75mm diameter material into the guide-holes.