Wings for a sailplane

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Published on November 26, 2012

Description

I am planning to create a 100% printable sailplane.
The profile is based on SD7037.
ATTENTION:
Please don't print any of this parts for use!
Just take them for information. Meanwhile a lot of the parts have been changed!
Here are current files: thingiverse.com/thing:86982

Instructions

The wing sections will be bonded together and additional tightened end-to-end by an 8 mm carbon pipe. The 4 mm holes are only for adjustment.
With 14 wing parts and two wing centre sections you will reach 1370 mm wingspan.
For printing use 1 perimeter and about 8% infill or rather less.
I don't know when I will continue the rest of the plane. In the meantime it would be great if anybody else looks to the fuselage or the tail unit. Or make some suggestions?

Edit: 13.01.2013
I added new parts as follows:
wing_90_infill
tail
fin_145
fin_rudder
fin_rudder_mount
horizontal_tail-middle_right
horizontal_tail-middle_left
horizontal_tail_ outside
horizontal_ rudder_ right
horizontal_ rudder_ left
horizontal_ rudder_ outside
horizontal_ rudder_ mount

At the beginning I planned to design the plane without motor and RC. In the meantime I think I should go a step further. But that brings some problems to place the servos, motor and RC. Probably I have to make the fuselage bigger. If I get the components I will see.
I hope it will not change the tail because I have it ready together with the complete tail unit.
Another problem is how to split the fuselage in pieces so most can print them. The current tail is 145 mm.

All fin parts have holes for to dowel them together. 2 mm for 1.75 filament and 3.2 mm for 3.0 mm filament. These are only for adjusting. Of course additional they must be glued.

The inner horizontal rudders and the fin rudder have support on underneath its mounts. The inner ring on the frontside of the tail is also a support. These must carefully break off or cut off afterwards.

Before fitting the horizontal middle fins to the tail you must remove very accurately the jutting edge of the first layer. Especially the inner nooks of the vertical nose have to be file off carefully.
Then the horizontal fins will fit exactly and tight to the tail and you almost don't need rubber bands for fastening :-)

The tail and rudder parts I printed with 0.25 mm layer height, 1 perimeter and 0.025 infill.
The rudder mounts with 0.2 mm layer height, 3 perimeter and 0.5 infill.

New wing profile
To save weight I designed a different wing profile with infill structure (wing_90_infill.stl) But there is one difference: the 4 mm hole is now 4.5 mm more backwards. This became necessary to bring the perimeters of both together.
Attention:
Please be aware that the small holes of the two different profiles will not fit together.

The next 7 weeks I will not have an opportunity to work on it. So don't expect any progress in this time.
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the plane looks great.. will be interested to hear how it flies.. :)

Hi northshore, are you still interested?

You won't hear it but you can SEE how it flies ;-)
http://www.thingiverse.com/thi...

I am glad you like it.
I detected that the 8mm carbon tube is much oversized. 6 mm tube would also do it.
Square tube has more stability than round tube but in my case I can't use it. It is to difficult to print long square holes that fits to the tubes because printed square holes have always rounded edges.
It is also easy to bore up a round hole if it is to narrow.
Yes, I am also curious about how it flies. One can be for sure - it certainly will fly downwards ;-)

surprised you would need 8mm CF rod / tube..?... I use 6mm square CF tube, is great for this size wing and hugely strong. I'm using 3mm sq for wings up to 800mm... :)

 nice idea (i had the same sometime ago) with somes issues with wrapping , delamination 
i tryed with 2 perimeters sliced with  slic3r hexagonal filling 0.1 density, added some small réinforcement with no good result or with prohibitive weight.

I finished with only printed ribs with balsa sheet

I print with ABS whet do you use ?

I use PLA and for slicing Skeinforge.
On the print bed I place the trailing edge of the wing to be on the left front side. In Skeinforge I take for "Start From Choice" the "Lower Left". This has the advantage that you will have the side bolster (bulge) that comes with each layer only on the trailing edge.

nice... will look forward to seeing the completed design, have had issues with AUW and balance on smaller models and finished up with a good solution on a powered plane with a 1300 - 1400mm wingspan also.

You can find fuselage, tail and elevator designs I have posted for reference as required.

Thank you for your tip. I will have a look at the really good parts you designed. With the wing tips I will reach also 1400 mm.
In the meantime, couldn't you print my wings and replace them on your plane for testing? ;-)