Creating your own long-distance 3D printed drone brings together a mix of innovation and creativity. You’ll start by becoming familiar with the design and slicing process, where digital files transform into tangible parts ready for assembly. The drone’s compact yet powerful CAD-designed frame boasts a 130-watt battery, vastly surpassing conventional options, granting you around 40-50 minutes of flight time and a ten-mile range. By the time your print is ready, you’ll have a sturdy, efficient framework that’s ready for the skies.
To build your own aerial marvel, you’ll need a set of essential tools and components, all available from convenient online sites. From the precision of a SpeedyBee V3 F7 Flight stack to robust 22mm brushless motors, each piece plays a pivotal role in your drone’s performance. With straightforward guidance on completing the build, including soldering and assembling the various parts, your journey will not only teach you the technical art of drone creation but also leave you with a thrilling sense of accomplishment as you pilot your creation across the skies.
In this video, you create a long-distance flying 3D printed drone and follow all the steps to assemble it using parts available from Amazon.
Your 3D printed drone packs a monumental amount of power into a compact CAD-designed frame. You could almost call it a flying battery, as it features a 130 Watt battery capacity to power the drone. This battery is three times stronger than a conventional DJI battery pack and will offer you approximately 40-50 minutes of flying time with up to a 10-mile range.
Using a 22mm brushless motor with 7” tri-blade propellers, it is driven with the latest SpeedyBee V3 F7 Flight stack. If you wish to create this 3D printed drone, you can 3D print the drone main body and lid using the STL CAD design files provided below and order the parts below to follow along with the assembly.
CAD STL Design 3D Print Drone Files:
Main Body – https://cdn.goengineer.com/body_long_…
Components Lid – https://cdn.goengineer.com/lid_long_d…
Products Featured:
SOLIDWORKS CAD: https://www.goengineer.com/solidworks…
Stratasys F370 3D Printer: https://www.goengineer.com/3d-printin…
GrabCAD Print Software: https://www.goengineer.com/3d-printin…
Below are the links for the items you need to purchase. To complete this build, you will need a soldering iron, heat shrink, 5 m3x10mm screws, M3 tap, and a metric hex screwdriver.
3D Printed Drone Parts:
1X 2207 1800kv Brushless Motors ($62.99) https://www.amazon.com/dp/B07TK6WS1R?…
1X SpeedyBee V3 F7 ($123.99) https://www.amazon.com/dp/B0B5QYXJNT?…
1X 6S 5200 Mah LiPo Battery ($69.99) https://www.amazon.com/dp/B083NW11ZJ?…
1X ExpressLRS lite receiver ($18.99) https://www.amazon.com/dp/B09M6SLFFQ?…
1X Runcam Pheonix 2 JB edition ($35.99) https://www.amazon.com/dp/B08BNNQZ8G?…
1X AKK Race Ranger 1000mW VTX ($24.99) https://www.amazon.com/dp/B07YC1BSX6?…
1X Foxeer lollipop VTX antenna ($21.99) https://www.amazon.com/dp/B07D12XS6K?…
1X XT60 Plug for battery connector ($8.99) https://www.amazon.com/dp/B07QH249CR?…
Total $367
Optional Parts:
Runcam 5 4k Action Camera with SD card ($125.99) https://www.amazon.com/dp/B082Z16S54?…
iFlight FPV goggles ($92.99) https://www.amazon.com/dp/B08RJFTJDY?…
GPS Module ($29.99) https://www.amazon.com/dp/B078Y6323W?…
1X BetaFPV ExpressLRS remote control ($54.99) https://www.amazon.com/dp/B09J8N2QW8?…
Want to learn more about FDM 3D Printing? Check out this page:
https://www.goengineer.com/3d-printin…
Website: https://www.goengineer.com
Blog: https://www.goengineer.com/blog
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Get To Know GoEngineer:
Collaboration and partnership with you is at the core of everything we do. With more than 35 years of experience and thousands of customers in high-tech, medical, machine design, energy, and other industries, GoEngineer provides best-in-class design solutions, carefully selected to be easy to use, manage, and integrate with other platforms. We are also delighted to support Educational communities as the National and Global leader for Colleges, Universities, and schools.
Planning and Designing Your Drone
Determining the purpose and specifications
When you embark on the journey to build your own 3D-printed drone, the first step is to determine its purpose. Whether you’ll be using your drone for photography, racing, or simply as an exciting DIY project, your intentions will influence the specifications you need. Considerations might include the weight your drone must carry, the desired flight time, range, and speed. These factors will guide aspects like the size of the motor, type of battery, and aerodynamics. Drawing up a list of your primary goals for the drone will help ensure the design meets all your expectations.
Choosing the right design software
Picking the right design software can streamline the creation process. Software options like SolidWorks, Fusion 360, or Tinkercad each come with their unique strengths. The right choice will largely depend on your comfort with 3D modeling. Tinkercad, for example, is very beginner-friendly, whereas programs like SolidWorks might offer more advanced features necessary for complex designs. Select a tool that aligns with your experience level and the complexity of your project, ensuring you have the necessary resources and support to bring your vision to life.
Understanding drone aerodynamics and physics
To design an efficient drone, you’ll need a fundamental understanding of the physics and aerodynamics involved in flight. Concepts such as lift, thrust, drag, and weight play a crucial role in how your drone will perform. Understanding these principles will assist you in making educated decisions about the shape and structure of the frame, the size and type of propellers, and the positioning of various components. This knowledge ensures your drone is both efficient and stable when airborne, providing a solid foundation for a successful build.
3D Printing Basics
Introduction to 3D printing technology
3D printing is a transformative technology that allows you to create physical objects from digital designs. It works by adding material layer by layer to build your drone’s components. Familiarity with how 3D printing functions will help you in troubleshooting and optimizing your prints. Understanding the basics, such as how different printers (e.g., FDM or SLA) operate, and knowing the strengths and limitations of each technology, will aid you in selecting the most suitable setup for your drone project.
Selecting appropriate materials for drone parts
When 3D printing, selecting the right material is crucial. The most common materials for drone parts are PLA, PETG, and ABS. PLA is easy to print with but may not withstand high temperatures. PETG offers a good balance between strength and flexibility, while ABS is known for its toughness but requires careful handling due to warping issues. Your choice should be based on the specific needs of each drone component, considering factors such as durability, flexibility, and environmental conditions.
Calibrating your 3D printer for optimal results
To achieve high-quality prints, you need to calibrate your 3D printer. Proper calibration involves setting the correct bed leveling, nozzle height, and extrusion rate, among other factors. These adjustments ensure that your parts will have the right dimensions and finish, reducing the need for extensive post-processing. Regular calibration checks can prevent printing mishaps and inconsistencies, leading to a smoother printing experience and better quality drone parts.
Creating 3D Models for the Drone
Designing the drone frame using CAD software
The drone frame is the critical foundation of your 3D model. Using CAD software, you can create a detailed design tailored to your project specifications. Start with the frame’s skeletal structure, considering where components like motors and batteries will fit. Use the CAD tools to test various stress and weight distribution scenarios, ensuring your frame is both lightweight and robust. Successful CAD design lays a solid groundwork for effective 3D printing.
Generating STL files for 3D printing
Once your CAD design is ready, the next step is to convert these models into STL files. STL files are the standard for 3D printing as they map the surface geometry of your 3D models. Few software programs allow you to directly export your design as STL files. Ensure your settings are correct to maintain the integrity and detail of your design. Careful generation of STL files guarantees that the printed parts will meet your design’s specifications.
Strategizing the layout for each part
Arranging your parts in a logical and efficient layout within your 3D printing software can enhance the printing efficiency and reduce material waste. Group smaller parts together and lay them flat for better adhesion. Plan the orientation of each part to minimize support structures and improve the surface finish. Strategic layout planning reduces printing time and material use while increasing print quality.
Preparing for 3D Printing
Using slicing software effectively
Slicing software is integral in converting your 3D model into instructions your printer can understand. It slices your model into horizontal layers and generates corresponding G-code. Experiment with slicing settings such as layer height, infill density, and wall thickness to improve strength and print time. A good understanding of how to use slicing software will allow you to tailor each print to its specific needs, optimizing performance and output quality.
Setting the print parameters
Fine-tuning your print parameters is essential for successful 3D printing. Parameters include nozzle temperature, print speed, and bed temperature. Each material might have different optimal settings, so you’ll need to adjust these to suit your chosen material. Setting accurate parameters prevents issues like warping, stringing, or layer misalignment, ensuring that your prints come out perfectly every time.
Estimating print time and material usage
Before hitting print, it’s helpful to estimate how long your print will take and the amount of material it will use. Most slicing software provides estimates that can guide you in planning and preparing for the printing process. Knowing the expected material usage allows you to ensure you have sufficient filament and manage your time effectively. This foresight can prevent mid-print interruptions and streamline your drone assembly workflow.
The 3D Printing Process
Starting your print job
Starting your print involves final checks to ensure everything is set up adequately—double-check the model’s orientation, print settings, and material-level prep. Once satisfied, begin your print job. Ensure the first layer adheres correctly to the print bed, as this is critical for the success of the whole print. Once everything is running smoothly, let the printer work its magic as it brings your drone parts to fruition.
Monitoring the printing progress
Monitoring the print is crucial as issues can arise like layer shifts or filament jams. Be on the lookout for symptoms of problems such as inconsistent extrusion or parts lifting from the bed. Employ a regular check-in routine, or use built-in printer cameras if available, to catch and rectify issues promptly. Keeping a watchful eye allows you to intervene in time should any problems develop, safeguarding the quality of your prints.
Time-lapse footage for long-duration prints
For long-duration prints, capturing time-lapse footage can be both practical and rewarding. It offers an insightful view of the entire printing process, which can be used for identifying potential improvements in future prints. Simply using a camera or a phone with time-lapse capabilities positioned strategically can document this creation journey, and also provide a captivating visual of your project taking shape layer by layer.
Post-Print Processing
Removing support materials
Once your print is complete, removing any support materials is the first step in post-processing. These supports are often essential during printing but must be carefully detached to avoid damaging your parts. Tools such as pliers or a hobby knife can be helpful for this task. Ensure you work methodically to maintain the integrity and quality of the printed parts.
Inspecting and cleaning printed parts
After support removal, inspect your parts for any printing flaws or damage. Sometimes there might be residual support material or irregularities that need addressing. Gently sanding the edges and surfaces can help in achieving a smoother finish. Also, ensure all interconnected parts fit together as intended, making adjustments if necessary. Thorough inspection and cleaning set the stage for a successful assembly.
Fine-tuning and testing part durability
Part durability is crucial, especially for something as complex as a drone. Subject your parts to stress tests to determine if they can withstand the mechanical demands. This might involve manually testing for flexibility and strength. Any areas of weakness should be reinforced, potentially using stronger adhesive or additional support structures. By ensuring each component is as robust as needed, your assembled drone will fly safely and effectively.
Assembling the Drone
Attaching the motors and electronic components
With your parts ready, the assembly begins with attaching the motors and other electronic components. Using the appropriate screws and fittings, secure the motors in place, ensuring all connections are oriented correctly. Follow up by integrating components like the flight controller, ensuring all electronic parts are connected properly. This careful organization will provide reliability and ease of use once your drone takes flight.
Installing the flight stack
The flight stack, consisting of ESCs and the flight controller, is the heart of your drone’s control system. Carefully install each component in its designated socket, following the manufacturer’s instructions. Ensure a snug fit to avoid vibrations and loose connections, which can lead to mid-flight complications. The flight stack’s precision installation is crucial for stable and responsive flight performance.
Securing the propellers and batteries
The final steps of the assembly involve securing the propellers and inserting the batteries. Mount the propellers firmly, verifying they are balanced and set in the correct direction for optimal thrust. Insert the battery carefully, ensuring a secure connection that won’t disconnect during flight. Properly installed propellers and batteries ensure your drone operates efficiently and safely during flight testing.
Drone Electronics Setup
Configuring the Flight Controller
Setting up the flight controller involves firmware installation and calibration using appropriate software. The configuration process allows your drone to understand flight commands and respond correctly. By assigning specific actions to transmitter sticks or buttons, you tailor your drone’s responsiveness to your preferences. Properly configuring the flight controller is crucial for achieving precise handling and stable flight characteristics.
Connecting power distribution components
Your drone relies on a well-connected power distribution system to operate seamlessly. Wiring together ESCs, the battery, and motors demands a careful approach to prevent shorts and ensure current flow is optimal. Using proper soldering techniques and heat shrinks makes the build durable and reduces the risk of electrical failure. Ensuring secure power distribution connections is essential for a reliable flight experience.
Integrating cameras and transmitters
If your drone is equipped with cameras or requires real-time data transmission, integrating these components is the final step. Mount the camera securely, ensuring the transmission signal is clear, positioning the transmitter to maximize range and reduce interference. This integration provides the pilot with live feedback and control over the drone’s perspective, adding an extra dimension to your flying adventures.
Initial Flight Testing
Pre-flight checklist and safety measures
Before your maiden flight, a thorough pre-flight checklist ensures everything’s in place. Check propeller and motor integrity, battery life, control responses, and any extraneous equipment connections. Implement safety measures such as secure flight zones and observer awareness, which are important to protect both the drone and bystanders. By ensuring all systems are go, you set the stage for a successful inaugural flight.
Conducting test flights for adjustments
Your first flights should be approached cautiously, treating them as opportunities for adjustments. Start with hover tests to ensure stability before advancing to more intricate maneuvers. Take note and adjust the flight parameters like throttle response, trim settings, or component calibrations based on performance feedback. Patience in this stage is vital, as small tweaks can lead to significantly improved flight stability and control.
Troubleshooting common issues
Initial test flights may reveal areas that need troubleshooting, such as erratic movement or connectivity issues. Address these by methodically checking all connections, recalibrating components, or refining software settings. Common issues might be surprisingly simple fixes, requiring an observant and methodical approach to identify the root cause effectively. A problem-solving mindset ensures a steady path to building an efficient and reliable drone.
Conclusion
Recap of the build process
Congratulations on navigating the intricate process of designing, printing, assembling, and testing your 3D-printed drone! From initial planning and design to final assembly and flight testing, each step has brought you closer to your flight-ready creation. This comprehensive journey into drone building showcases not only your skill in 3D printing and electronics but also your capacity for innovation and creativity.
Final thoughts and improvements
As you reflect on the build process, think about potential improvements or modifications. Perhaps different materials, additional features, or alternate designs may spark your interest for a future project. Innovation is often fueled by curiosity and a willingness to explore new possibilities, leading to enhancements or fresh concepts.
Encouragement for DIY drone enthusiasts
For fellow DIY drone enthusiasts, your 3D-printed drone is a testament to what creativity and technology can achieve together. This accomplishment not only shows mastery over diverse skills but also expands the horizon for personal and shared exploration. May your success inspire others to embark on their own drone-building journeys, contributing to a growing community of innovators eager to explore the skies. Whether this is your first build or one of many, take pride in your creation and enjoy the endless possibilities drones offer. Happy flying!