January 2016 Hacker of the Month- Freebird Flight

Know-how and the most recent devices have all the time been an curiosity to me, however they have been confined to hobbies throughout my restricted free time as a monetary analyst for almost 20 years. I made a decision to take a while away from that world in early 2014 after  the 2008 monetary disaster results sapped the trade of quite a lot of the brilliant minds that had attracted me to it within the mid-‘90s. I hoped to unleash my creativity in creating one thing new the place I may make a distinction, and I used to be excited to lastly have a while to try this.

Naturally, I turned desirous about 3D printing, and acquired a Cubex printer. I started instructing myself do fundamental prints with the out-of-the-box software program, however I quickly found Fusion 360 from Autodesk and was rapidly making extra sophisticated designs. First on the listing have been customized child-safety objects like protected wall plates, knobs for stoves, and doorways to make the home safer for our twin boys who have been 1-year outdated on the time. I discovered I may make these things in simply the suitable dimensions to suit the {hardware} in our home in distinction to generic retailer purchased objects that sometimes fell wanting being really helpful.

A pair months later, I received a small drone, one other new expertise I used to be desirous about, and which have been simply changing into extra broadly out there. A number of weeks after that buy, like most new drone house owners, I crashed it in our again yard and broke one of many arms. As I used to be making an attempt to find alternative elements, I glanced over on the printer and it occurred to me I may in all probability make replacements. Having efficiently finished that, and studying extra concerning the drone expertise available in the market on the time, a few months later, I believed I’d attempt to develop one thing higher than what was out there – specifically one thing bigger that might be used for all types of functions – not simply video – and that was extra climate tolerant. That was summer season 2014.

By early fall, I had a working prototype – made principally from ABS and PLA. I had additionally upgraded to a Lulzbot TAZ 4 printer, which opened up an entire new universe of supplies that I couldn’t use with the proprietary Cubex platform. That’s once I found MatterHackers, which rapidly turned my single supply for filament. In October or November 2014, they launched Proto Pasta’s carbon fiber filament, which I rapidly tried. That was maybe the largest enabler for me to develop the present design. I may now print a lot thinner, a lot sooner, and with completely no warping. The design on the time, and which I caught with for a pair extra months after the carbon fiber was launched, extra carefully resembled a practice quadcopter with 4 arms. Even with the carbon fiber, I nonetheless had issues with arms breaking off over time due to the heavy load (as much as 25 kilos) being carried by the arms along with vibration from the motors.

As I turned higher at printing the carbon fiber and improved my CAD design expertise, I made a decision to overtake the design fully so as to print even thinner elements whereas on the similar time evenly distributing the load of the UAV and stress from the motors’ torque throughout the body. The present enclosed body design got here to me sooner or later – I nonetheless bear in mind – on a Friday in early January, nearly a yr in the past. The entire image was in my head. It was to be an airframe that enclosed the blades (for security), however in a method that truly elevated the power of the general body by distributing the car’s weight and motor torque stress evenly to keep away from focus of stress at simply 4 factors – one thing I now name a SurroundFrame. Even till now, I’ve not seen an enclosed body design that’s something greater than a physique cowl that sits on high of a conventional body with 4 arms – or a variation that has partial enclosures on the outer corners. In any case, whereas useful from a security perspective, they characterize added weight that reduces battery and flight time. It took me precisely every week to design and print the entire body and switch the motors and different electronics over from the prior design. That following Friday, the 3-foot diameter UAV (now known as Freebird One), was within the air.

I knew this was the design I used to be after, however a lot work was nonetheless wanted. It was lighter than my outdated design, however nonetheless too heavy. Flight occasions have been 8-10 minutes with giant batteries. It weighed 20 kilos or so. The wiring couldn’t stand as much as the excessive present pull. A few occasions it even caught fireplace within the air! Because it was winter on the time, electronics and motors have been repeatedly destroyed by flying within the snow. Even so, I found the primary different use for a big UAV with quite a lot of prop wash: an airborne snow blower. It was good for as much as 4 inches or so of snow and will clear our driveway in minutes operated from inside the nice and cozy home! However it may do much more than an everyday snow blower. It cleared snow off the vehicles after which off the roof of our home.

My mission was clear at that time: I had one thing highly effective that might fly very exactly and by itself. However it wanted to fly loads longer, be loads lighter, deal with any form of climate, carry quite a lot of tools and attachments that I’d wish to develop for varied duties — and do all this with out sacrificing power. I caught with carbon fiber for probably the most half, although efficiently produced one unit totally with wooden fiber filament from MatterHackers final summer season. Further supplies within the present model embody Ninjaflex for climate covers and vibration dampening and clear Bluprint for the cockpit cowl to make the lights from the 3D Robotics Pixhawk flight controller seen.

The underside line is that quite a few iterations and a yr later, I’ve created a 100% printed giant UAV from an concept in my head, a improbable CAD package deal from Autodesk, a strong workhorse printer from Lulzbot, and prime quality, dependable (all the time 2-day free ship throughout the nation) filament from MatterHackers, specifically Proto Pasta’s carbon fiber. The one bought elements are the electronics and propellers, although I’ve efficiently printed propellers that work, and will finally swap to printed props after testing is accomplished. The UAV is even assembled utilizing printed carbon fiber pins, which changed conventional stainless-steel screws I had been utilizing earlier.

Not solely is Freebird One 100% 3D-printed, however I might argue its efficiency specs beat something available on the market in the present day. It now weighs simply 8 kilos with out a battery (half of what it weighed the primary time I made it). It may fly for as much as 35 minutes, has most speeds of 70MPH horizontally and three,000 ft/minute vertically, can carry an extra 15-20 kilos of payload due to extra 6,000 watts (9+ horsepower) from the 4 brushless motors, and is totally weatherproof (snow, rain and winds as much as 50 MPH or so). It’s additionally the most secure UAV.

My hope for the longer term is so as to add synthetic intelligence options to help in impediment avoidance and expanded failsafe options similar to a parachute and skill to search out protected locations to land within the occasion of an issue that precludes the UAV from returning dwelling. Equally necessary, I hope to develop quite a lot of attachments to broaden performance of Freebird One as a helpful “software”. Snowblowing is only one instance, however even that might be improved with attachments I take note of. I additionally efficiently used it this fall as a leaf blower. And since the blades are enclosed, I used to be in a position to take away impacted leaves alongside fences by bumping the UAV alongside the fence and angling the airflow in a strategy to get below the leaves. In the same capability, the UAV works nicely as a gutter cleaner with a 3D Digicam (in a 3D-printed weatherproof case) sending a reside video feed  to a pair of goggles, permitting for exact maneuvering in tight spots. The chances are limitless – each for shoppers and companies.

Freebird One will probably be commercially out there within the close to future.  After having issued RFQs for injection molded elements, it isn’t clear that I can get elements made to the tight specs I’ve been achieved by way of 3D printing.  Given the character of this venture, each gram of weight issues loads, and specifically the strength-weight dynamic. Each 100 grams represents roughly one minute of flight time, and each gram of fabric must be exceedingly sturdy. In consequence, the present plan is to truly construct up a 3D printer “farm” to provide elements rapidly. I’ve improved print settings to the purpose the place the elements coming off the printer require little to no post-processing. At 20 um decision utilizing carbon fiber, the traces aren’t very seen and look extra like a sample than what conventional 3D-printed elements seem like. Utilizing 3D printing as a producing answer additionally allows me to revise and enhance elements rapidly, introduce new attachments, and supply customized modifications with out utilizing a typical replace cycle.

So far I’ve been engaged on this enterprise alone, however will probably be increasing within the close to future. I actually treasure the time I’ve spent on this thus far. Not solely have I been in a position to spend extra time with my household, however I’ve been in a position to simply dream up new concepts after which truly produce them proper earlier than my eyes. Much more than the UAV I’ve created, I stay amazed on the potentialities opened up by 3D printing and prime quality consumer-accessible CAD software program. It’s a fantastic age we reside in the place somebody like me with no engineering background can design and produce a top quality plane within the confines of my dwelling with nothing greater than an concept, a pc, a 3D printer, just a few spools of filament… and a few persistence.

If you’re desirous about studying extra about Freebird Flight, you possibly can go to Roger’s website or comply with them on Fb, Instagram, and Twitter.

Do you assume you could have what it takes to be our subsequent Hacker of the Month? Merely comply with us on Fb/Twitter or e-mail media@matterhackers.com. Inform us about your venture or 3D printed creation, and you can be featured in our subsequent e-newsletter. The Hacker of the Month may also win a free spool of PRO Collection PLA or ABS filament to additional their pursuit of 3D printing greatness.