Body Parts

The Copter Parts STL files are designed to be created using 3D printing.

The primary 3D printing method for these designs is FDM (filament) printing. Some parts may benefit by using SLA (resin) or SLS (powder) printing.

All parts can be FDM printed using the most common PLA filaments. The filament attributes that are most important are:

• Stiffness
• Layer Adhesion

The additional strength of advanced materials such as ABS and PETG might be beneficial for some parts such as the landing gear legs. Because all parts can be easily and cheaply produced and replaced, the benefits of advanced materials may be small.

I’ve used Polymaker PLA-Pro for most of of the body parts for this quad copter. The key feature of this material is it’s “stiffness.” Quad-copters require most parts to be stiff to avoid vibration.

Flexible Body Parts using TPU

Two parts that benefit from flexibility are the battery tray door and the landing gear feet. TPU filament may be a good choice for these parts.

The landing gear feet are optional – and can be omitted. The Battery Tray Door may also be substituted with a battery strap.

Transparent Body Parts

Transparent materials allow visibility through the lid’s dome to the quad-copter’s internal electronics.

The clearest material I’ve tried is clear resin using SLA printing.

Translucent materials such as translucent PETG may also allow seeing LED indicators on the quad-copter’s electronics.

Vendors such as PCBWay will make this part for about $10 with clear SLA resin and polishing.

Fasteners

The body pieces are assembled using M3 screws. The XT-60 plug is attached with M2.5 screws.

These are some recommended fasteners:

• Metal M3 Flange Head screw – These have a broad and shallow head that is necessary for attaching a motor to the Motor Mount Plate and the Arms to the Fuselage Body.
• Metal M3 Button Head screw – These have small heads for greater clearance that is useful for attaching a Motor Mount Plate to an Arm.
• Nylon M3 Phillis Head screw – The fuselage body is drilled and tapped for M3 screws to attach the Battery Tray and the Landing Gear Legs. Nylon screws have less risk of stripping these threads.
• Metal M3 Nylock nuts – to secure the motor mount plates to the arms and the arms to the body.
• Metal M3 washers – to distribute the load under M3 Nylock nuts.
• Nylon M3 standoffs – to allow mounting the Equipment Tray above the flight controller.
• Metal or nylon M2.5 screws – to secure the XT-60 plug

Adhesives and Adhesive Tapes

The only place an adhesive is required is to attach the Lid to the Lid Dome. Almost any common adhesive will work. I’ve used small drops of hot glue.

Double sided adhesive tapes are commonly used to attach electronics to surfaces. Some commonly used in sUAS construction are:

• 3M VHB – This material is very thin ad strong – and almost permanent.
• 3M Foam tape – This material is strong and can add some vibration relief.
• Double sided “nano” tape – This tape is marketed under various names. It’s typically about 2mm thick and feels “gummy.” It holds well but may be easier to remove than VHB.