Plane 1:

Objective:

My brother and I are fascinated by aeronautics and have owned several RC planes and drones over time. We decided to design, build and fly our own creation.

Brainstorming process:

We researched different types of planes online and learned about the principles of flight. Ultimately, we chose a flat bottom wing profile with dihedral(Wings slightly bent upwards like a V) for stabilization and classic plane design. We created multiple templates before settling on the final design.

Assembly:

We laid out templates on the foam, then cut out pieces and glued them together. Next, we wired the electronics and put them in place.

Results:

Success! The plane flew through the air and we had a blast flying it. However, we knew we could improve the design.

Cutting out the pieces of foam

Building the wings

The plane in flight

Plane 2:

Objective:

Although the first plane flew well, it was unstable and tricky to fly due to asymmetries. Thus, we set out to make piloting less awkward. We also wanted to incorporate 3D printing to test the impact of using different materials.

Brainstorming process:

After additional research, we chose a more trainer-plane oriented design. We modeled and 3D printed multiple variations of each piece. We also experimented with different types of filament before choosing a special type of foaming PLA.

Assembly:

After 3D printing the final versions of each component, we sanded and glued each piece together. Finally, we wired the electronics and put them in place.

Results:

Success! The plane was easier to fly and flew well for a short stint. Then, disaster struck when I got a little too cocky and crashed it.

Full set of 3D printed components

Gluing the components together

The final product

Plane 3:

Objective:

While the second plane flew well, its durability was lacking. We overestimated the strength of the foaming PLA, which was badly damaged after a particularly strong crash. We realized that it would be too difficult to keep repairing the plane so we sought a more durable design.

Brainstorming process:

We decided to return to the original foam design, as it was very durable. However, the 2nd generation plane design functioned the best so we made a hybrid version using the same trainer plane design. We wanted a larger plane that flew more slowly for greater stabilization.

Assembly:

We cut out the foam using templates and glued the pieces together. We then assembled the electronics and attached them to the plane.

Results:

The plane flew perfectly. Although it was the longest surviving plane, it ultimately crashed and the wings were bent beyond repair.

Finished plane

Assembling the electronics

Plane 4:

Objective:

The third plane flew well, with many crash-free sessions. However, one particularly bad crash permanently bent the wing (unrepairable) and the wing length proved too large for the small cross-sectional area. So, we decided to change the style of the plane entirely.

Brainstorming process:

To get the most strength, we decided to go with a mono-wing plane that was incredibly strong.

Assembly:

We cut out the foam using templates and glued the pieces together. We then assembled the electronics and attached them to the plane.

Results:

The plane flew perfectly. It was able to do loop-de-loops and fly upside down, among other aerobatic stunts. The Wright Brothers were in business!

Assembling the electronics

Finished plane

Flying the Plane

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