Show HN: I made a 3D printed VTOL drone
This is the thing I'm most proud of building to date!
Before this project, I was a total CAD, 3D printing and aerodynamic modeling beginner. I had only built and flown one VTOL before.
SPECS
Wingspan: 3.9 ft (1200 mm) Length: 2.5 ft (770 mm) Weight: 5.6 lb (2.55kg)
Airframe: foaming PLA (Bambu PLA-Aero) and PETG structural parts printed on A1 printer, CFRP booms and spars
Battery: Li-ion silicon anode Amprius SA08 cells, 6s2p pack by Upgrade Energy Motors: 2807 AOS for lift and cruise (unoptimized) Lifting ESCs: 4 in 1 Holybro Tekko32 F4 45A Cruise ESC: Flycolor Raptor 5 45A Lifting and cruise props: 7042 Gemfan (unoptimized)
Flight controller: Speedybee F405 Wing GPS: M10
Firmware: Ardupilot 4.6.0
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This video edit ended up shorter than I planned. Being my first Youtube video with significant post production effort, I underestimated the work required to make a longer in-depth video with voiceover, edited footage, etc.
I wonder if the reduction in weight from the now unneeded servos would pay for the extra battery drain.
I have 4 batteries, which means I basically need to be refilling my batteries as quickly as I consume them in order to keep flying continuously (unfortunately, even with a quad-charger, I cannot fully sustain this.)
I would LOVE to have a fixed wing drone that could fly over the area and snap close-to-nadir photos as it did so, but the complexity of building and programming a hand built drone seems so much higher than deploying an off the shelf DJI drone. Additionally, the land is steep, with a 1,000+ foot elevation difference, and rugged, and the neighboring land is airspace I cannot fly within, so I couldn't use it to perform my turns.
Author, or others, any thoughts on whether it's worth pursuing a fixed wing aircraft to perform this mapping mission? Or is the best bang for my buck to just buy enough batteries to fly the mission continuously on an off the shelf quadcopter?
Never used one, but either this design or a tri-rotor v-22 style tilt motor are the two designs I've found intriguing. Worth checking out at perhaps?
https://www.uavmodel.com/products/makeflyeasy-hero-2180mm-ua...
This one has a maximum climb rate of 3 degrees. Which means you'd need to plan a route that's continously climbing, and tacking back and forth to avoid going steeply. So you would probably combine flight planning using Mission Planning: https://ardupilot.org/planner/ and custom json tweaking following MavLink protocol: https://ardupilot.org/dev/docs/mavlink-routing-in-ardupilot....
The open source flight controllers and systems are https://ardupilot.org/copter/docs/common-autopilots.html#ope... a good place to start. There's a few orgs building the full experience, but you'll of course pay for fully integrated, but still open source, hardware+software.
The scenario you describe is exactly what a VTOL or normal play is for; quad copters simply do not cover enough ground.
Also consider the camera. DJI typically ship with really low quality cameras, but https://www.bhphotovideo.com/c/product/1785754-REG/sony_ilx_... would get you a much higher pixel density so if you're more interested in the imaging, you can flight higher, near the licensed ceiling, completing more ground faster.
I've also found AI models know how to calculate pixel densities, so it's pretty easy to mock out a flight plan even if you dont have the actual drone available.
I'd probably go for some Sony Experia 10III[¹] or upwards, for no more than 300$ at 170 g (unmodified), and strip the hell out of it. Does it need a display, all the parts of the case, and so on? Can can I use its GPS, and pipe it into the flight controller, instead of having to rely on something more powerful and heavy, power guzzling?
[¹] because https://xdaforums.com/f/sony-xperia-10-iii.12225/
cf. https://en.wikipedia.org/wiki/Ingenuity_(helicopter)
I dont know much about the weights involved, but hardware surgery was not interesting to me.
Keepbin mind tge guys starting at DJI and youre proposing stripping dowm a camera
There really is a full open source hardware/software path, which is heartening.
For your needs, a slow-stick with a KFM wing would suffice - the smallest, lightest, simplest, most capable airframe one can build, and that is a slow-stick[0] with KFM wings[1].
VTOL is cool for those of us raised on a healthy sci-fi diet, but is entirely unnecessary for a slow-stick, which can be hand-launched directly into the air (vertically) and landed at a stall within a meter.
Plus, it is small, light, effective and extremely simple, which means its a lot easier to repair and maintain. Add some ardupilot magic and you've got a really capable platform for surveys and reconnaissance.
tl;dr Consider building a small fleet of slow-stick+KFM planes, attach your camera to it, and do your survey that way ..
[0] - https://www.rcgroups.com/forums/showthread.php?1395335-Begin...
[1] - https://www.flitetest.com/articles/kfm-wings-a-basic-explana...
If anyone wants to try this: The parts he uses are all standard Chinese-made COTS you can buy on amazon and similar.
The ArduPilot firmware he uses is very flexible and robust, but setting it up is one of the worst UXs I've experienced. Commercial UASs almost universally use PX4 instead.
But my first and only other VTOL build was foamcore Readyboard and that took a 12 ft drop onto asphalt with only a slight compression in the fuselage. Never replaced it.
I would add dovetails or other clips for printed sections if I did another printed build.
Yes avionics and propulsion parts are COTS for speed, the Amprius pack is US manufactured but others are all made in China.
I'm starting to see some more Ardupilot used commercially too but yes the UX is janky and unintuitive.
The big advantage is that you can just print the part again, which almost makes PLA worth it.
ABS would probably be better, as it's much more durable and lighter, but it's still much heavier than foam, and printing ABS isn't great.
https://ardupilot.org/planner/ - the website seems down right now though.
And if you're looking for other ground controls, you could try out QGroundControl or Mavproxy (terminal based).
How much customisation did you need to make to Ardupilot? Is your drone's control unique, or somehow standardised?
What I started with - Had built one VTOL before from foamboard, not 3D printed. - Familiar with Ardupilot from that project and assembling a multicopter and COTS VTOL. - So I had a little experience building a structurally sound airframe for VTOL loads, but 3D printing was a wrinkle. - How I worked it out is a hard question. But it was being focused with design, flight testing and troubleshooting. LLMs, Youtube, forums, etc for help when needed. - Building in public helped paradoxically. It actually saves me time to build in public because of the motivation boost that helps me move faster and to share progress sooner. Even though there's a higher lift to document and share.
The HUD overlay you’re referring to is technically Mission Planner (GCS software), not ArduPilot (flight control software). Mission Planner and ArduPilot both talk Mavlink, and they’re both developed by the same community. MP is flexible. You can set it up to do almost anything you’d ever want. It’s also terrible and exceptionally janky… but extremely powerful. And they’re both free.
I think the problem with both of them is that they’re good enough that there isn’t likely to be a huge critical mass developing a better alternative. On the GCS side there is also QGroundControl and APM Planner 2 (which was a fork or reimplementation of Mission Planner). Both of them have their own upsides and downsides, but neither one of them is as mature or as powerful/flexible as Mission Planner. PX4 on the flight controller side is popular commercially because it’s BSD-licensed instead of GPL, but the net result is that it has nowhere near as many features as ArduPilot because companies build proprietary features and don’t push them back upstream.
This stuff is definitely in the worse-is-better domain. ArduPilot is free, ArduPilot is amazing and ArduPilot sucks. :)
Anyway, off to bed. I’m in a long test campaign right now and we’ve got to be up at 0430 to fly the ArduPilot-based aircraft again before the weather goes sideways.
He has separate motors for vertical and horizontal flights, which simplifies the design, but creates a rather bad inefficiency, the vertical motors create lots of drag during the horizontal flight.
Maybe it's not a big deal, I'm not sure. Making motors rotate would add weight for sure, thus reducing the range.
https://en.wikipedia.org/wiki/Wing_Aviation#/media/File:Wing...
Adam Savage did a video tour of their factory recently, worth a watch
Thanks! https://www.youtube.com/watch?v=_BXm6dTHvY0
I'm a big Waymo and Wing fan, but hadn't seen that.
With this config, the cruise motors and prop are optimally sized for cruise - which gives non trivial gains to both eta for propulsive motor efficiency and prop efficiency.
Vs a tiltrotor/wing/body in which the cruise motor has to do double duty as lifting motors. Given it takes anywhere from ~4-7x more power to hover (depending on disc loading) than to cruise, you can see how the motors are not in an optimal throttle/rpm band in this case. Archer's CTO Munoz has actually said this publicly.
Tilt-rotor on all 4 motors with an extra twist: the wing shape adds to the lift in vertical mode, so you can use smaller motors, so they're more efficient even in horizontal mode.
> the wing shape adds to the lift in vertical mode
Wings require airspeed to work, which there presumably aren't a lot of in vertical mode.
This is also the most the penalty will ever be as electric motors continue increasing in specific power, and quite rapidly this century so far.
Incredibly humbling! “””
The imagination to reality loop is most rapidly well-tuned for categories that exist.
Did you do the whole airplane with a small printer like the A1 / A1 mini? I would love to print airfoils but I'm struggling to imagine a way to link individual prints together in a way that preserves stiffness. My 100cm wing would need 10x (10x10cm) printed parts somehow attached to one another.
Until I figure this out it's foamboard building for the type of airplanes I want to build (glider)
It would definitely have been tight on an A1 mini but the full size A1 would work great for sure.
I have a question, though: Any info about the flight stack? Was it Pixhawk/Ardu, iNav, or something else?
Or I could probably add another ~0.5 lbs or a little more without issue. The lifting motors hover at 45% ish throttle so there is some headroom for more payload without reducing battery mass fraction.
At first, I was like "Nah, just looks like my RC car battery", but then I Googled it...and it's a whopping $1,305 [0].
I looked closer at the specs and they're insane for a battery as small as it is. They have double the energy density as measured by both volume and mass compared to my RC car batteries [1].
[0] https://www.upgradeenergytech.com/product-page/gold-v1-6s2p-...
[1] https://www.amazon.com/Zeee-Connector-Vehicles-Helicopter-Ai...
Would love to try my hand at reproducing the work you did!
Either way, nice work!
hope I can build mine 3d printer lab first
edit: at least 70 mph
https://www.youtube.com/watch?v=wThmg8Ezm9w