3D printing the parts you need

Here's a technique for using 3D printing to create parts for your RC aircraft.

To quote Wikipedia: "3D printing is the process of making a three-dimensional solid object of virtually any shape from a digital model. 3D printing is achieved using an additive process, where successive layers of material (plastic) are laid down in different shapes."

Creating 3D objects using an appropriate printer is becoming increasingly common and price of printers is coming down. If you don't want to go all-out and buy your own 3D printer, there are plenty of companies who will do the job for a modest fee.

I recently discovered that clever designers of 3D objects often upload their digital designs so that anyone can download and use the pattern to print the objects, or modify them to suit their own needs. The most commonly used site for such designs is the Thingiverse. A link is provided below. Spend some time checking out the objects that are possible with 3D printing; you'll be amazed!

There is a whole section for RC objects, everything from helicopter parts to battery cases. Among the RC objects I found a version of the Flitetest firewall that the designer used on his FT Versa Wing. I downloaded the file and sent it to a local company for printing. The resulting object is incredibly light and strong. Be aware, however, that the 3D printing process doesn't produce the lovely smooth finish seen in the digital rendering of the image. The process produces a textured finish, caused by the depositing of successive layers of plastic. The finish can be smoothed using acetone, or simply sanded smooth. Here are some images to illustrate the digital image, the object being prepared for printing, and the finished product.

The firewall object as seen in the Thingiverse online catalogue.

Here is the firewall being scaled and prepared for printing.

I ordered eight copies, which were printed in a single session.

The finished firewalls. On the left you can see the rough texture produced by the printer. On the right is one that has been quickly sanded.

What does it cost? That depends on the deal you make with your local printing company. The eight firewalls I had made, plus an initial prototype, came out at around $5 each. On balance, the costs are reasonable but probably not attractive enough to forgo using ply or other materials, or to stop supporting Flitetest by buying items from the store. That said, it's an interesting idea, don't you think?

Links:
The Thingiverse: www.thingiverse.com
3D Flitetest firewall : www.thingiverse.com/thing:175413