This is more for fitment testing rather than functionality, but I decided to take the design I had for aluminum arms for the Mini-Quad and have them 3D printed by Shapeways. As you might have guessed the design is inspired by the Lumenier QAV400 arms. While they are similar I have added my own design features and lightened them where I could. I ran a quick FEA on the aluminum version and they should deflect less than .005" under full thrust (using 6061-T6 aluminum). This is with the mounting points fixed, so most likely in flight they should flex even less.
I had them printed out with the "Strong and Flexible" plastic material on their website. They look pretty, but they definitely have noticeable flexibility. I went ahead and installed them on the frame with the motors just for kicks and giggles. It definitely wouldn't be flyable with these printed arms. I would have to beef up the design a lot more if I wanted to print useable arms.
I had them printed out with the "Strong and Flexible" plastic material on their website. They look pretty, but they definitely have noticeable flexibility. I went ahead and installed them on the frame with the motors just for kicks and giggles. It definitely wouldn't be flyable with these printed arms. I would have to beef up the design a lot more if I wanted to print useable arms.
Unfortunately shortly after I received the printed mock-ups, I was informed by my machinist friend that he probably wouldn't be able to machine the aluminum versions due to work issues. Because I want to keep the project moving along, I have already re-designed the arms to be made out of flat .125" G10-FR4 plate, which is currently being machined by Twitchity from the Flite Test Forums (he also milled my frame plates). The new arms should work out good, but I was really hoping to have a unique mini-quad with machine aluminum arms (which would eventually be anodized).
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