3dp Flying Whirligig

thingiverse

The STL file is just a placeholder for now, so please don't assemble or fly the other files you've downloaded yet. I apologize for any inconvenience this may have caused. Print Settings Printer Brand: Robo 3D Printer Model: R1 ABS + PLA Model Rafts: No Supports: No Resolution: Low Infill: Solid Notes: Use 100% infill and 2 perimeters layers for the blades, wing sleeve, wing retaining pins, wing sleeve socket, launch axle, and launch handle. For the launch tube, 20% infill and 2 perimeter layers will do. Post-Printing Assembly and Flying Remove the flashing from all parts and give them a moderate sanding. Be sure to pay extra attention to the blade roots, the blade slots in the wing sleeve, and the twist socket and where it inserts into the blade sleeve. Sand with medium sandpaper as necessary to get a firm but not too hard fit for the blades and socket. Round the corners of the blade roots slightly so they will fit into the sleeves easier. Use a hobby file to open up the sharp angle where the back of the blades fits into the blade sleeves. The twist socket fits into the bottom center of the blade sleeve, with the thin-walled, square-looking side projecting slightly out of the bottom of the sleeve. The top, twisted-looking end of the socket projects from or is even with the top of the blade sleeve. Drill 1/8 inch holes through the blade/sleeve assembly .3 inch back from the blades leading edge and .15 inch in from the outer edge of the wing sleeve. Enlarge the holes enough for the pins to slide all the way through the sleeve and blade. This puts the pins through the thickest part of the blades, halfway between the wing sleeve bottom and its outer edge. I used Plastruct Bondene solvent cement, wicked into the blade/sleeve, socket/sleeve, and wing retaining pins/sleeve/blade joints to reinforce them. I allowed the plastic to re-harden overnight with good ventilation and avoided exposure to the fumes since the solvent contains potentially harmful chemicals. Attach a medium-sized rubber band near the top of the launch axle and attach enough chord to the rubber band to allow pulling the chord back to your chin (about 40 inches in my case). The rubber band helps avoid damage to the launch axle if you suddenly hit the end of the chord and helps the chord grip the shaft. Rub wax onto the axle where it contacts the top of the launch tube. Make sure the top edges of the launch tube are smooth. These steps will help prevent plastic erosion where the spinning axle contacts the stationary launch tube. The chord end is attached to the pull handle by passing the chord through the small hole in the handle. You'll probably need to clean the hole with a small drill bit or small round file for the chord to pass through. I used waxed nylon chord to get maximum strength and tied a loop in the chord end after passing it through the handle, then put the loop over the shaft. Don't use weaker chords like hemp because they are not strong enough. Wind the rubber band and chord clockwise (viewed from the top) around the launch axle between where it projects from the launch tube and ends in the twisted plug. The plug at the top of the axle should fit completely into the socket in the blade sleeve with a bit of friction as it reaches maximum insertion. If the plug doesn't fit completely into the socket, turn the blade sleeve 90 degrees and try again, as sometimes the fit is slightly different. Place marks on the wing and axle plug to more easily find the best alignment. Give yourself plenty of grassy space to fly in. The prototypes have flown more than the length of a soccer field with significant wind. If there's wind, pointing slightly into it can bring it back closer to you. For safety, keep the Whirligig above your head during the launch just in case a blade comes loose. Keep all spectators significantly back out of the way for their own safety. Pull slightly down on the string during the launch to keep the launch axle in the launch tube. At the end of the launch, pull the rotary wing should naturally slip out of the axle plug and fly away. If the wing pops off prematurely and doesn't rise, you may have wound the chord backwards. If it pops off prematurely and rises to a low altitude, insert the blade sleeve socket more fully into the axle plug. Pulling too weakly on the chord during a launch can allow the wing to prematurely separate from the axle plug. The wing needs to continuously accelerate to the end of the pull for the axle plug to grip the wing effectively through the entire pull. This is not a children's toy. If used carelessly, it could cause injury. Be careful! Please let me know your experiences with the Whirligig. Thanks, Mike