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No-Screw Micro-Quadrocopter ~14-16cm

by Schorhr, published

No-Screw Micro-Quadrocopter ~14-16cm by Schorhr Oct 6, 2012

Description

Before I never upload it, here is a ever-lasting work-in-progress.

Idea 2009, first frame from Shapeways 2010, finaly made one for FDM this year.

Seems like nothing new these days, but back then it was :-)

I completely changed the frame, and it is completely screw-/glue-/tape-less!!!1!!11!1!!!one!!!

Print, clip in components, fly.
Crash, clip in components, fly.

ROBUST!

Recent Comments

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Yes, but busy with other things :-( Other then the length of the first prototypes I was rather pleased with the results though.
Hello
Are you still working on the project ?
Same here (PP3DP UP+).

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Instructions

I included a STL of the latest test print.
It still consists out of multiple object shells and needs to be customized to the parts you want to use.
It's also a good idea to make the landing gear more durable, this will be adressed in a future version.

Print:
Print upside-down.
Rotate 45° to print on a small printbed (UP) for example.
Use more infil for a rigid frame, less infil for a light frame.

Setup:
KK-Board from Hobbyking
5g, better 10g brushless motors
TURNIGY Plush 6A
2 or 3S 500mAh LiPo + RubberBand
Cheapo-2.4GHz 6CH rX
AirAce 3blade (Don't run these on full throttle @ 3S constantly, or use other motors!)

ToDo:
Finding the right settings is a bit difficult with these little ones...
Making the motor holders longer depending on the prop size
Making the electronic compartment deeper or shorten the wires (else it's messy).
Make landing gear even thicker to be even more rigid
Test the camera holder.
Hello
Are you still working on the project ?
Yes, but busy with other things :-( Other then the length of the first prototypes I was rather pleased with the results though.
How big of a print area does this require?
Schorhr - in reply to
Hi, the ~146mm version (mesured from each outside the motor holder) will require ~106x106mm printbed if rotated 45°. With ~175mm outer dimensions, it would need a ~127x127mm printbed.
Cool (since I have 140 x 140).
Schorhr - in reply to
Same here (PP3DP UP+).
You know, some STL files would be in order here.

-M
Fixed. As it is not final and does not fit every part, I did not include a STL. The uploaded STL is for the 10g motors and the other parts I posted. 
I was curious how much it would cost to build this, so I put together this spreadsheet using items mostly from Hobbyking:
https://docs.google.com/spreadsheet/pub?key=0Are357CLq6WndFB0bnNOX3RUajFKNzNYWm ZnR3N3eEE&output=html

Add $24 if you need a transmitter, as one sells with that receiver for $38 as a package.

I can't tell from the images on this thing, but it seems they only sell the KK2 board now which includes an LCD (and perhaps weighs more). Is that the one in use?

Can't find any details on those propellers. They're listed at one vendor, but are not in stock. Alternatives? 
Printable alternatives? :)
I completely forgot:

I used buddycodes to get most hobbyking stuff cheaper AND split orders into parcels <22€ to avoid import tax :-)
(Strange, why don't I get notifications from Thingiverse anymore?)
http://disqus.com/thingiverse-2167fcf808b8f383e7e44e25305a08a8/ : That's about the right shopping list :-)

KK-Board: They will both work (same footprint) though the new ones have ACC = easier to fly for such a small copter IMHO.
KK2.1 is the "old" board, the numbers can be a bit confusing
http://www.hobbyking.com/hobbyking/store/uh_listCategoriesAndProducts.asp?idCategory=657  
Some other boards like the Multiwii seem popular too, or see

hobbyking.com/hobbyking/store/__19534__HobbyKing_Multi_Rotor_Control_Board_V2_1_Atmega168PA_.html

With the AirAce blades: 5g BL 2S lipo-> 63g thrust / 1,7A 
http://der-frickler.net/modellbau/brushless#uh_d1400-2000_5g
As an educated guess (Interpolated from similar props) the 10g motors should deliver 90g thrust at 2S, and draw 2A,  3s:4A/180g.
But of course using a board without LCD and shorteing the wires will help :-)

Props:
http://www.amazon.de/Acme-AA1110-Propellerset-ACME-Modellen/dp/B000LOXUVQ/ref=sr_1_1?ie=UTF8&qid=1349764321&sr=8-1
http://www.microtoys.de/product_info.php?info=p312_ACME-AirAce-Propeller-Set-AA1110.html
Some ebay sellers send internationally though;
http://www.ebay.de/itm/Propeller-Luftschrauben-Set-fur-AirAce-III-ACME-AA1110-/370660568824?pt=RC_Modellbau&hash=item564d176ef8
http://www.ebay.de/itm/AirAce-Propeller-Set-/310361812215?pt=DE_Allesf%C3%BCrKind_Spielzeug_FerngesteuertesSpielzeug&hash=item4843016cf7
There you can find the product ID# to order them locally.
Please note that Hobbyking has a whole bunch of small counter rotating props at small sizes, and that the current frame is a bit too short for the airace (plus pulling down the board-holder arms will give more space for components).
I played arround with printing props, but I'm no aerodynamics expert and I am also scared what will happen if layers rip appart in mid air ;-)
I ordered those but have not tried them:
http://www.hobbyking.com/hobbyking/store/uh_viewItem.asp?idProduct=11326
http://www.hobbyking.com/hobbyking/store/uh_viewItem.asp?idProduct=11327
http://www.hobbyking.com/hobbyking/store/uh_viewItem.asp?idProduct=18778
Even with the AirAce they are hard to get on the 10g Shaft, but I just drilled them out with a no-power hand-drill. Fits tightly, without prop saver (as they are not suitable for threeblades).
It's all a little trial&error with small quadrocopters ;-)

Transmitter/Receiver:
Sometimes Shipping will kill the good deals at Hobbyking. I ordered my second Radio at ebay, as they will sometimes be available for under $30 including shipping, thus import is tax free here (22€ tax free value, under 26€ nothing will be charged as the tax/custom fee would be under 5€ ) 
At least the 35MHz 6CH programmable radios where available for that price, seems they have finaly vanished, though they where ideal for a cheap solution to fly with a wireless camera (as they usualy interfered with the cheap 2.4G radio)
http://www.ebay.de/itm/F03104-A-FlySKY-FS-6CH-2-4G-FS-CT6B-RC-Transmitter-6channel-No-receiver-for-Heli-/251124188258?pt=LH_DefaultDomain_0&hash=item3a782b0462
IIRC Hobbyparz or whatever the name was had cheap radios, too.

With $30 RTF quadrocopters beeing available (including transmitter) building one seems stupid these days , but it's allways more fun... Plus those 10g brushless motors can lift quite some extra load (camera etc.)
"Seems like nothing new these days". We're still not to the "print 'n fly" quad copter, so I call this a win. It's new to me.
Probably as print-and-fly as it gets ;-) Next would be to print/mill a PCB... ;-)
This is truly an awesome thing!
Thank you! :-)
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