RC Airplane Construction

December 15, 2019

Today, aircraft manufacturers are using 3D printing as a new manufacturing process. From rapid prototyping to mass production and even the printing of spare parts at maintenance sites, 3D printing is revolutionizing aspects of the aerospace industry. Let’s try printing an airplane ourselves!

I decided on a radio-controlled model, which is simpler to print than a full-sized tourist aircraft! It’s a replica of the Savage Bobber, a light aircraft produced by Zlin Aviation in the Czech Republic.

I began by “slicing” the 3D files, which means generating layer-by-layer instructions for the 3D printer to execute. I’m using CURA, a 3D file slicer, with the parameters recommended for printing this airplane. Unlike a CNC machine that removes material, a 3D printer must extrude the correct amount of plastic per layer. Over-extrusion can lead to incorrect dimensions, while under-extrusion can result in lower resistance to mechanical stress.

After the printing is complete, I clean each part to remove imperfections and blemishes.

Once all the parts are printed, we can proceed with assembly. The fuselage is a plastic framework made up of several pieces glued together with cyanoacrylate adhesive. Despite its delicate appearance, it’s quite robust!

The wing halves consist of three parts: a wingtip section and two central sections, each approximately twenty centimeters long. The total wingspan is about 90 centimeters.

The hinges are printed from a flexible rubber material with a Shore hardness of 85A, allowing the control surfaces to be moved effortlessly by the micro servo motors.