Full RC Hawker Hurricane - 3D printed project

cults3d

For a long time now I wanted to start from scratch and build myself a 3D printed plane. So here I am after almost 80 hours of printing and assembling, with this beautiful aircraft ready for its maiden flight. I designed this plane using Autodesk Inventor and Fusion 360, taking inspiration from various aircraft designs and adapting them to fit my specific needs. The fuselage is made up of several sections, each printed separately and then assembled together. The wings are made from a combination of carbon fiber and aluminum, with a custom-designed rib system to provide additional strength and stability. The control surfaces are also designed for optimal performance and maneuverability. I used a variety of 3D printing technologies throughout the build process, including FDM, SLA, and SLS. Each technology was chosen based on its specific strengths and weaknesses, and I experimented with different settings and materials to achieve the desired results. The aircraft's propulsion system is powered by a custom-designed electric motor, which provides a high level of efficiency and reliability. The battery pack is designed to provide a long flight time, and the power management system ensures that the aircraft stays within safe operating parameters. Throughout the build process, I encountered several challenges and setbacks. However, with the help of online forums and communities, I was able to troubleshoot and overcome these issues. Now that the plane is complete, I am excited to take it on its maiden flight. I have performed extensive testing and simulations to ensure that it is safe and stable, but there is always a chance for unexpected issues to arise. I hope you will be able to build this plane and enjoy flying it as much as I have enjoyed designing and building it. If you do decide to build it, please post pictures and videos of your progress so that we can all learn from each other's experiences. General Printing Instructions: For all the parts use Cura Creawsome Mod if you have a FDM printer. It seems to be fusing the filaments better and it has ironing functions on almost every layer. This results in compact prints. Print all the parts at 0.1 to 0.2mm resolution. I printed all of them at 0.2mm layer height. It's recommended to increase the printing temperature with up to 5% of your regular one for that specific type of filament you use. This could create oozing but the structures would end up more compact. I used 210⁰C for black and blue PLA. Fuselage A section: The solid block one 4 shells, 6 top and bottom layers Trim the window section and the flat base with the soldering iron after printing. The perforated one Trim the window inner walls and make a hole into the flat base after printing to make it more lightweight. Fuselage B,C,D sections Use support materials and print as they are. Aligning the fibres horizontally will give the parts the needed torsion strength. I used the line support pattern from Cura which comes off easily. I had almost no infill. I matched up the number of the shells with the number of top/bottom layers so I would get a pretty much solid print. Next time I would try to use only 3 shells and up to 4 top/bottom layers to make them lighter and use less material on them. Fuselage E,F sections Reorientate the F piece nose down. I think I uploaded it nose up. So flat base down because this flat base will be the motor attachment plate and it needs to be compact. Be careful. Use at least 20 bottom layers for this F section so the motor will not be attached on a thin paper like shell. Print the E section as it is and don’t rotate. I printed both of these sections with no supports. Cowl The long one looks better on the plane and fits nicer with the F section of the fuselage. I uploaded the short one too so you could install the one that fits better according to the size of your motor. Both of them prints with no supports, nose down. I think I uploaded the short one nose up so you will need to rotate it. If you decide to go with the short cowl, you would probably need to make the flat motor mounting plate of the F section less sharp around the edges. I had to fillet these edges with about 5mm to make the short cowl fit properly. Exhaust arrays 2 to 3 shells 10% infill Attach permanently to the cowl using glue or spot welded with the soldering iron. I heated them up a little bit with the heatgun before gluing to the plane just to give them a curled shape that would follow the line of the fuselage better. I used 4 screws (2.5X8) to attach the cowl to the fuselage as you can see in the pictures. Wings and middle section I generated the line support using Cura and I aligned the lines with the wing ribs. Check the last picture in the list for example Cockpit Print using line support material. 2 shells, 4 top layers 0% infill trim the cockpit interior and attach it to the fuselage.