3D Printed Drone Frame Lesson/Lab with the Hubsan X4

thingiverse

Project #8 - Recreating the Hubsan X4 Micro Drone: 3D Printed Drone Frame Lesson/Lab This project requires a lot of different components, and with the right parts, makes for an incredible learning experience for students in any introduction to robotics/technology/engineering class. Utilizing a custom frame, such as the one in this project from user Islemunda, students can reassemble a new drone from using a 3D printed frame with the electronic components of the Hubsan X4 drone. Where 3D printing comes in handy with this project is the ability for different student groups to design their projects around different ideas of how to improve the flight capability of their drone, such as increasing/decreasing the thickness of the printed parts or adding additional support items. The advances in 3D printing and in the filaments that are available for use have allowed makers to make improvements and adjustments to different cases for many devices. In this case, a classroom setting offers many applications of engaging in such a project as students will be given a creative opportunity to recreate, and even improve, the function of a pre-existing device - in this case, a microdrone. This hands-on experience will allow students to apply engineering design principles to real-world problems. Objectives: * Students will disassemble a microdrone (Hubsan X4) into its electrical components. * Students will design/modify a custom drone frame for the creation of a new microdrone through 3D printing. * Students will reassemble a custom drone using the electrical components from the Hubsan X4 and their 3D printed custom drone frame. Lesson Plan and Activity: Duration of classes: This project will require at least 5 separate classes to complete all the steps. 1st class - debrief activity and show appropriate videos on assembly process of Hubsan X4 2nd class - disassembly process of the Hubsan X4 for each group 3rd class - 3D designing and modifying of drone frame + 3D printing them 4th class - assembling new drone with the electrical components from the 2nd class and the printed frame from the 3rd class 5th class - calibrating and testing new drone for flight Step 1: Show videos of assembly process of the Hubsan X4 to students Step 2: Brief students on the project and requirements. Step 3: Have students break into groups of 4 Step 4: Distribute microdrones to each group and initiate the disassembly process Step 5: Supervise students on disassembly process and ensure safety when using tools (especially the soldering iron) Step 6: Ensure students label and properly store all of their group's electrical components as they finish with the disassembly process Step 7: Allow students to create/modify a new drone frame for their microdrone (can utilize the provided STL files) Step 8: Finalize drone frame designs and 3D print all of them Step 9: Have students reassemble the drone utilizing the electrical components from the Hubsan X4 and additional support items (adhesives, solder, double-sided tape, etc.) Step 10: Teacher now should check each group's drone to make sure things are put together safely and accurately (check for broken wires, missing parts, etc.) Step 11: Calibrate the drone for the appropriate controller (See video below) Step 12: Test each drone for flight! Step 13: Debrief activity with students and brainstorm for next steps in possibly upgrading their project to do other things (ie: better camera, propellers, etc.) Materials Needed: * Tools Required: + Soldering Iron + Wire Cutter + Wire Stripper + Screw Driver * Electrical Parts/Drone Parts Required (from the Hubsan X4 drone): + Flight Controller Module Rx + Body Shell + Motors + 4.Propellers + Rubber Feet + Blue LEDs + Red LEDs + Screw Sets + Protection Cover + Battery + Charger + Transmitter + Wrench Preparation: * Adequate workshop/class space * 3D printers to make the custom drone frames * Safety goggles for students using the soldering iron * Safety gloves * Computers/laptops with 3D modeling software to make the custom frames Rubric and Assessment: None. Teacher should assess students based on the overall design and function of each group's drone. References: * http://www.nextgenscience.org/dci-arrangement/hs-ets1-engineering-design * http://www.instructables.com/id/SIMPLE-GUIDE-TO-MAKE-a-QUADCOPTER/