PROJECT OVERVIEW

10-13-2024

The goal of this project is to create a method of quickly and cheaply reinforcing 3D printed parts so they can be used in durable UAVs.

Just Started

Working on it

Complete

INITIAL EXPERIMENTS

10-18-2024

I started more or less knowing I would want to use a single layer of carbon fiber, but I'd never fabricated any composites before, so I decided I would start making test parts until I was happy with the results I got to familiarize myself with the process. I ended up printing an airfoil section from Bambu Labs ASA-Aero and coating it with 2K 2x2 twill carbon fiber and Totalboat epoxy. Vacuum bagging was used to create a good surface finish and an ideal resin-to-carbon fiber ratio.

FIRST WING RESULTS

10-18-2024

The first wing I made was a success, but had some very large flaws. The vacuum bagging worked flawlessly to create a very strong and lightweight part, but the surface finish was extremely rough due to the peel ply used. The 3D part didn't have enough infill to resist the forces of the vacuum bag and as a result it warped pretty severely.

First wing attempt top view, the infill pattern is clearly visible which is not good

First wing attempt side view, notice the unacceptable warping

SECOND WING RESULTS

10-21-2024

The second wing I made was even more of a success. I increased the infill density by 15% which barely increased the weight of the part but drastically increased the resistance to the vacuum bagging process. I also used a different peel ply which left a much smoother surface finish. The part was also post coated and sanded to further improve the surface finish.

FULL AIRFRAME

12-10-2024

I created a full carbon fiber drone, as designed in Autonomous Drone Software. The full airframe is extremely durable and roughly equivalent to the same airframe if it were printed in ABS.

Parts of the drone during the clear coating step

A 3D-printed jig was used to keep the fins stabilized during the joining process

The surface finish is good and I am happy with the parts, but they are a lot of work to make properly. My next steps will be to use a stabilizer in the carbon fiber so I can cut it to shape while it is still a fabric, and the use of a completely smooth peel ply to achieve a good surface finish with no post processing (no sanding or clear coat).