UAV fuselage 3D Printed in Nylon for Lightweight and Strength

thingiverse

I've begun 3D printing UAV fuselages for a friend starting in the hobby, using "Bixler" frames with horizon sensors. With increasing tall obstacles, crashes on foam and covered planes led him to seek help. So far, I've printed around five different-sized, -shaped fuselages based on his request, all 3D Printed in Nylon for light weight and axial stability due to circular printing pattern. The friend is satisfied with the nylon's pliability and strength, surviving several rough landings and pole collisions without damage. These parts measure 200mm tall, printed hollow (no fill) with 3-4 perimeters for strength; each extra perimeter adds slight weight. Axial strength is excellent due to circular printing pattern. The print pad is separated from the nose for customization. To ensure a good starting layer, design the print with 4-5 solid layers followed by hollow ones, stopping before it tries to print a top. This creates a lenticulated surface slick at .16-.18mm height; larger layer thickness can be smoothed with acrylic coating. Fuselage diameters are slightly smaller to fit into others, adjustable based on perimeters. Printing material is 618 Nylon from Taulman3D. Additional assembly details found here: http://www.diydrones.com/profiles/blogs/uav-fuselage-3d-printed-in-nylon-for-lightweight-and-strength. The friend is now enjoying more flights with his new fuselages, only facing grass stains and tar on the nose and sides; however, he's out of wings.