Plastic Beast

thingiverse

This is a detailed design document for a quadcopter frame made from 3D printed ABS plastic. The design aims to balance power and strength while minimizing weight. **Design Overview** The frame uses a "true X" motor configuration with standard standoffs for the top plate, measuring 35mm. The baseplate weighs between 100-105g, while the topplate weighs between 4-6g (or up to 8g for a GoPro mount). Camera mounts weigh 2g. **Design Challenges** The design initially faced challenges with blocking too much of the prop thrust area when using a "X" configuration. After three iterations, the current design achieves a balance between power and strength. **Print Settings** To achieve optimal results, the designer recommends using Simplify3D or similar software to adjust print settings: * Baseplate (100-105g): .2m print height, 27% 60-degree triangular infill, 4 print layers for bottoms, 3 print layers for sides * Top plate (light version, 4-6g): .2m print height, 27% 60-degree triangular infill, 3 print layers for top, 4 print layers for bottoms, 3 print layers for sides * Top plate (GoPro version, 6-8g): .2m print height, 30% 60-degree triangular infill, 3 print layers for top, 4 print layers for bottoms, 3 print layers for sides * Camera mounts (2g): .2m print height, 27% 60-degree triangular infill, 3 print layers for top, 4 print layers for bottoms, 3 print layers for sides **Assembly and Installation** * Mount the ESC on the center plate instead of the arms to reduce weight. * Install two ESCs upright on both sides of the FC and two more on top of each other on the back section of the center plate. * Use a zip tie to secure the VTX antenna to the back of the top plate. * Run cables from motors to ESC through small channels in the arms. * Install the battery strap before mounting the PDB. **Experimental Settings** For a more durable quad but at the cost of 11g additional weight, the designer suggests using: * Baseplate (115-120g): .2m print height, 30% 60-degree triangular infill, 4 print layers for top, 4 print layers for bottoms, and 4 print layers for sides. **Notes on Build** The design incorporates tolerances to accommodate differences in printer accuracy. The camera mounts have tight tolerances, requiring a small amount of plastic removal with an exacto knife to achieve a snug fit. Cables from motor to ESC should be 3 1/4 inches long, and the battery cable is designed to exit the front of the quad frame.