Super Light Quadcopter

thingiverse

The ultimate goal of this project is to take the thrilling flight experience of the legendary Hubsan X4 quadcopter to new heights, quite literally maximizing its airborne duration and battery life. To achieve this ambitious objective, only spare parts from the incredibly fun Hubsan H107L model were utilized. Weighing in at an astonishing 4.18g, the chassis is coupled with a mere 0.49g battery clip, making the total quadcopter weight, including chassis, clip, LED's, motors, propellers, and receiver, an unbelievable 21g. With the battery excluded from the equation, this impressive model is a staggering 25% lighter than its original H107L counterpart, which tips the scales at a hefty 27.8g. Even when paired with a 380mAh battery, it still manages to be only 3.5g heavier than the H107L without its power source. With the battery in tow, this phenomenal model comes in at an incredibly lightweight 31.35g, whereas commercial alternatives hover around a whopping 38.15g. The Continuous flight time with a 380mAh battery was meticulously measured to be a whopping 11.5 minutes. Those fortunate enough to have access to a H107L for comparison are cordially invited to share their results. Due to its remarkable low weight, this exceptional model is incredibly quick and reactive, making it an absolute blast to pilot. While robust enough to handle some flight-related stress, it's crucial to remember that this project is optimized for minimal weight rather than excessive ruggedness. Should you decide to print the chassis with 100% infill and utilize a different material, it may be able to withstand more damage. To facilitate improvements or modifications, the original Rhino CAD file has been made available for your convenience. For those eager to dive deeper into the construction process, detailed instructions and recommended parts can be found here: http://www.instructables.com/id/Super-Light-Quadcopter/. The print consists of a cleverly designed body that perfectly accommodates original Hubsan parts from the H107L model, including the receiver, 7x20mm motors, 3mm LED's, and battery. The innovative clip not only secures the battery but also provides an added layer of stability for the cable. A noteworthy update has been made to adjust the battery cable clip for a better fit. Please check out this video: http://youtu.be/ML9STN5LbJ8 Instructions: The body is ideally printed upside down to maximize structural integrity. For enhanced robustness, printing with 100% infill is highly recommended. I've successfully paired Simplify3D software with the Wanhao Duplicator 4x printer and PLA material to produce exceptional results. For more detailed settings and print configuration information, please refer to the images from Simplify3D. It's also advised to employ manual support structures as per the accompanying images. You'll find my project files for Simplify3D in case you want to utilize exactly my settings and support structure. Extrusion width: 0.46mm Layer height: 0.1mm Top solid layers: 5 Bottom solid layers: 5 Shells: 1 Infill: 10% with 50% extrusion width @ 75 & -25 degrees Support infill: 30% and offset 0,25mm Temp extruder: 218C Temp bed: 60C The battery clip can be printed using the same settings, except for adjusting printer width to 0.42mm and extrusion multiplier to 0.99.