How to 3D Print RC Plane

3D printing has revolutionized the way hobbyists build RC (radio-controlled) airplanes, offering immense customization, precision, and affordability. Whether you're an experienced flyer or a maker looking to build your first plane, this guide will walk you through the entire process of 3D printing your own RC aircraft. We'll cover materials, settings, electronics integration, and answer key questions, as well as highlight some of the most popular 3D printed RC plane models available today.

Steps to 3D Print an RC Plane

1. Choose Your 3D Model

Before printing, you'll need to find a 3D model of an RC plane that fits your needs. Several online platforms like Thingiverse and Cults3D provide various free and paid RC plane designs. Here are some popular designs:

• GASB Four: Simple, just 4 parts.
• Northern Pike RC Airplane: A 36-inch flying model.
• GASB One: A fully 3D printed flying wing with only 9 pieces and no glue required.

Each model has different flight characteristics, so select based on your skill level and goals (e.g., long flight times, speed, or acrobatics).

2. Prepare the 3D Model for Printing

Once you have chosen a model, it's time to prep it for your 3D printer. Download the STL files and import them into slicing software like Cura or PrusaSlicer. This software will allow you to adjust settings to ensure the print meets your requirements.

3. Optimize Printer Settings

For RC planes, weight and durability are crucial. Here are some key settings to adjust:

• Layer Height: Use a layer height of around 0.2-0.25mm for a balance between strength and print time.
• Infill: An infill of 10-15% should suffice. Use hexagonal or gyroid infill to keep the model light and strong.
• Wall Thickness: Set the wall thickness to 2-3 layers to ensure durability without making the plane too heavy.
• Print Speed: Reduce the print speed to around 40-60mm/s for smoother surfaces and fewer defects.

Make sure to use supports if your model requires them, especially for complex components like the fuselage or wing mounts.

4. Select Materials

Choosing the right material is essential for flight performance. PLA, PETG, and lightweight composites are commonly used for 3D printed RC planes.

• PLA (Polylactic Acid): This is a popular material for beginners due to its ease of use. It’s lightweight and strong but can be brittle.
• PETG: PETG provides a balance between flexibility and strength, making it less prone to breaking on impact. It is, however, slightly heavier than PLA.
• Lightweight PLA (LW-PLA): Specifically designed for lightweight models, LW-PLA expands as it prints, reducing weight and improving flight performance.

5. Print the Components

Once the settings are dialed in and material is selected, print your parts. Depending on the complexity of the plane, printing all the parts may take several hours to a few days. It's important to monitor the prints for warping or layer separation, especially on larger parts like the wings.

6. Assemble the Plane

Most 3D printed RC planes will require some form of assembly once the parts are printed. This includes:

• Joining Wings: Some models use interlocking parts or adhesive to connect wing sections.
• Attaching Fuselage Sections: Depending on the design, you may need to glue or screw fuselage parts together.
• Mounting Control Surfaces: Install hinges for ailerons, elevators, and rudders as necessary.

7. Install Electronics and Controllers

Once the frame is assembled, it’s time to install the electronics that will bring the plane to life.

• Motor: Install the motor in the designated motor mount area.
• ESC (Electronic Speed Controller): Connect the ESC to the motor and position it within the fuselage.
• Servos: Place servos at the control surface points (ailerons, elevators, rudder) to manage their movements.
• Receiver and Battery: Secure the receiver for communication with your transmitter, and place the battery in a balanced position within the fuselage.

Skills Needed for Electronics Assembly:

• Basic Soldering: You may need to solder connectors or wires for the motor and
• Wiring and Connector Knowledge: Familiarity with wiring configurations, such as connecting the motor to the ESC and the ESC to the receiver, is crucial. Use bullet connectors for ease of assembly and maintenance.
• Servo Installation and Calibration: You'll need to know how to install and configure servos for proper movement of control surfaces (ailerons, rudder, elevator). This involves positioning the servos correctly and ensuring the control rods move freely without binding.
• Receiver and Transmitter Binding: This involves pairing your RC receiver with the transmitter (remote control). You'll need to follow the specific binding process for your RC system, often involving powering on the receiver while holding a bind button.

8. Final Assembly and Balancing

After all electronics are installed, the final step is to balance the aircraft. The center of gravity (CG) plays a critical role in ensuring stable flight. Check the CG position specified by your chosen model's designer and adjust the position of the battery or add weight to achieve the correct balance.

• CG Check: Most designs specify where the CG should be along the wingspan. Use a balance tool or your fingers under the wings to check.
• Control Surface Setup: Test the movements of the ailerons, rudder, and elevator by using your transmitter. Ensure they move in the correct direction and make fine adjustments using the transmitter's trim options.

9. Test Flight

Before your maiden flight, double-check all control surfaces and electronics. Test the motor, servos, and any additional electronics (such as FPV cameras if installed). Once you're ready, launch the plane in a safe, open area. Start with a few short, easy flights to adjust the trim and make sure everything is functioning as expected.

Materials and Settings for 3D Printing RC Planes

1. Best Materials for 3D Printed RC Planes

• PLA: Common for beginners, easy to print, affordable, but slightly brittle.
• PETG: A step up in flexibility and durability, but slightly heavier than PLA.
• LW-PLA: Lightweight PLA is the premium option for RC planes. It expands during printing, reducing the overall weight, which improves flight performance.
• Carbon Fiber Nylon: For advanced users, carbon fiber-infused nylon is ultra-strong and lightweight, but it requires a high-end printer capable of handling such materials.

2. Printer Settings

• Layer Height: 0.2-0.25mm for a balance between resolution and speed.
• Infill: 10-15%, preferably using a gyroid or honeycomb pattern for weight savings.
• Print Speed: Slow down to 40-60mm/s for higher print quality and fewer defects.
• Supports: Use for overhangs like wing tips and fuselage openings.

Electronics and Controllers for 3D Printed RC Planes

1. Motor

The type of motor depends on the size and design of the plane. Common choices are brushless motors due to their high efficiency and power. They are available in different sizes and Kv ratings, which indicates the RPM per volt.

2. ESC (Electronic Speed Controller)

Match the ESC rating to the motor to ensure it can handle the current. A 30A or 40A ESC is typical for small to medium-sized RC planes.

3. Servos

Servos control the movement of control surfaces like ailerons, elevators, and rudders. Micro servos (around 9g) are commonly used for smaller planes, while larger servos are needed for bigger models.

4. Transmitter and Receiver

The transmitter (controller) is your interface with the plane, while the receiver installed on the plane communicates with the servos and ESC. Common brands include FlySky, Spektrum, and FrSky.

5. Battery

Lipo batteries (Lithium Polymer) are the go-to for RC planes due to their high energy density. A 3S (11.1V) or 4S (14.8V) battery is commonly used, depending on the motor’s power requirements.

Top 10 RC Planes You Can 3D Print

1. GASB Four - The First 3D Printed RC Plane in Just 4 Parts!

A simple and efficient design, perfect for beginners looking to print a functional RC plane quickly.

2. 36" Northern Pike RC Airplane

A sleek and well-balanced model, offering excellent flight characteristics for intermediate users.

3. GASB One - RC Flying Wing Fully Printed

This is a flying wing design, with only 9 pieces and no need for glue. It offers a streamlined, high-speed flight experience.

4. RC 3D Printed Plane (Recycled Filament)

An eco-friendly option that uses recycled filament while still providing a great RC plane design.

5. RC FPV Airplane - Model V Fuselage

Designed for FPV (First-Person View) flight, this model allows for immersive aerial experiences.

6. SuperOWL Jet 70mm EDF (Test Files)

A jet-style plane designed for use with EDF (Electric Ducted Fan) systems, offering high-speed performance.

7. TROY'S 3D Printed RC DC-6/DC-7 Airliner

A detailed model inspired by commercial airliners, perfect for those looking for a more unique flight.

8. RC Airplane TL Stream - Fuselage

Streamlined for better aerodynamics, this model offers great performance and ease of assembly.

9. VJet OWL v1 (Test Files)

 
A versatile design, perfect for both FPV flying and conventional RC use, with a focus on speed and control.

10. Full RC Hawker Hurricane - 3D Printed Project

 
A historical replica of the iconic WWII fighter plane, great for aviation enthusiasts and experienced RC pilots.

Troubleshooting Common Issues

When 3D printing and assembling your RC plane, you may encounter some challenges. Here are solutions to common problems:

• Layer Separation
  • Issue: Layers not adhering properly, causing weak points in the print.
  • Solution: Increase printing temperature slightly, ensure proper bed leveling, and check for drafts in the printing area.
• Warping
  • Issue: Corners of the print lifting off the bed, especially with larger parts like wings.
  • Solution: Use a heated bed, apply adhesive (like glue stick) to the print surface, and consider using a brim or raft.
• Stringing
  • Issue: Fine strands of plastic between parts, affecting aerodynamics.
  • Solution: Adjust retraction settings, lower printing temperature slightly, and enable "combing" in your slicer settings.
• Electronics Issues
  • Issue: Motors not responding or erratic behavior.
  • Solution: Double-check all wiring connections, ensure proper soldering, and verify ESC settings match your motor specifications.
• Balancing Problems
  • Issue: Plane tends to pitch up or down during flight.
  • Solution: Carefully adjust the center of gravity by moving the battery or adding small weights.
• Control Surface Binding
  • Issue: Ailerons, rudder, or elevator not moving freely.
  • Solution: Sand down any rough edges, ensure proper clearance in hinge design, and lubricate moving parts if necessary.

Remember, patience is key when troubleshooting. Make one adjustment at a time and test thoroughly before moving on to the next potential solution.

Post-Processing Techniques

Enhance the appearance and performance of your 3D printed RC plane with these post-processing techniques:

• Sanding
  • Use progressively finer grits (start with 220, end with 600 or higher) to smooth surfaces.
  • Focus on leading edges and other areas that affect aerodynamics.
• Filling and Priming
  • Use automotive filler to smooth joints and imperfections.
  • Apply a thin coat of primer to reveal any remaining surface issues.
• Painting
  • Use light coats of spray paint designed for plastics.
  • Consider using airbrush techniques for detailed designs.
  • Apply a clear coat for protection and added shine.
• Vapor Smoothing (for ABS parts only)
  • Use acetone vapor to smooth surfaces, but be cautious as it can weaken the part.
• Reinforcement
  • Apply thin layers of fiberglass or carbon fiber to high-stress areas.
  • Use CA glue (superglue) to strengthen joints and thin areas.
• Waterproofing
  • Apply a thin layer of silicone conformal coating to protect electronics from moisture.
• Balancing Propellers
  • Use a propeller balancer to ensure smooth operation and reduce vibration.

Remember to work in a well-ventilated area and wear appropriate safety gear when using chemicals or creating dust during post-processing.

Customization Tips: Adding Cameras and More

Customize your 3D printed RC plane to enhance its capabilities and your flying experience:

• Adding an FPV (First Person View) Camera
  • Choose a lightweight camera system (e.g., Runcam Nano 3 or Caddx Ant).
  • 3D print a custom mount that fits your plane's design.
  • Position the camera at the front of the plane for the best view.
  • Ensure proper ventilation to prevent overheating.
  • Use a separate battery for the camera system to avoid interference with flight controls.
• Integrating an Action Camera
  • Design a removable mount for cameras like GoPro Session or Insta360 Go 2.
  • Place the mount on top of the fuselage or under the wing for stability.
  • Consider the added weight and adjust your CG (Center of Gravity) accordingly.
• Custom Wing Designs
  • Experiment with different airfoil shapes using airfoil generation software.
  • Test various wing configurations (e.g., swept wings, delta wings) for different flight characteristics.
  • Use CFD (Computational Fluid Dynamics) software to simulate and optimize designs.
• LED Lighting Systems
  • Add LED strips along the wings and fuselage for night flying and visual appeal.
  • 3D print translucent parts to create unique lighting effects.
  • Use an Arduino or similar microcontroller to program dynamic lighting patterns.
• Modular Design
  • Create interchangeable parts (e.g., nose cones, wing tips) for easy customization.
  • Design a modular payload bay for different missions (photography, sensor packages, etc.).
• Performance Enhancements
  • Experiment with different motor and propeller combinations.
  • Design and print custom air intakes or ducts for improved cooling.
  • Create fairings and winglets to reduce drag and improve efficiency.
• Telemetry Systems
  • Integrate sensors (altitude, airspeed, GPS) for real-time flight data.
  • Use a microcontroller (e.g., Arduino Nano) to process and transmit data.
  • Design a custom housing for the telemetry system that fits your plane's aesthetics.

Flying RC Planes Legally and Safely

When operating your 3D printed RC plane, it's crucial to follow legal requirements and safety guidelines to protect both aircraft and people on the ground. Here are key points to consider:

• Registration:
  • In many countries, including the US, you must register your RC plane with the aviation authority (e.g., FAA) if it weighs over 250 grams (0.55 lbs).
  • Display your registration number on the exterior of your RC plane.
• Airspace Restrictions:
  • Never fly near airports, helipads, or other aircraft.
  • Use apps like B4UFLY (US) or similar local equivalents to check for flight restrictions in your area.
  • Respect no-fly zones around sensitive areas (military bases, power plants, etc.).
• Altitude Limits:
  • In most areas, RC planes must stay below 400 feet (120 meters) above ground level.
  • Always maintain visual line of sight with your aircraft.
• Safety Considerations:
  • Never fly over people or moving vehicles.
  • Avoid flying in crowded areas or during public events.
  • Choose open areas away from buildings and trees for safer operation.
• Weather and Visibility:
  • Only fly in good weather conditions with clear visibility.
  • Avoid flying in strong winds, rain, or low light conditions.
• Pilot Certification:
  • Some countries require a license or certification for RC plane pilots, especially for larger models.
  • Check your local regulations and obtain necessary certifications.
• Insurance:
  • Consider obtaining liability insurance for RC flying, often available through local RC clubs.
• Community Guidelines:
  • Join local RC clubs to learn about community-specific rules and best practices.
  • Participate in safety education programs offered by RC organizations.
• Privacy Concerns:
  • Respect others' privacy. Avoid flying over private property without permission.
  • If your RC plane has a camera, be aware of and comply with local privacy laws.
• Emergency Procedures:
  • Have a plan for safely landing or crashing your plane in case of control loss or technical failure.
  • Carry a basic first-aid kit and fire extinguisher suitable for electrical fires

Maintenance and Repairs of 3D Printed RC Planes

Proper maintenance and timely repairs are crucial for keeping your 3D printed RC plane in optimal flying condition. This section covers essential techniques and tips for maintaining and repairing your aircraft.

Regular Maintenance

• Inspection Routine
  • Before each flight, check for cracks, delamination, or loose parts
  • Examine control surfaces for smooth movement and proper alignment
  • Inspect propellers for nicks or imbalances
• Cleaning
  • After flying, remove dust and debris with compressed air or a soft brush
  • Clean electronics with isopropyl alcohol and a cotton swab
  • Avoid water-based cleaning methods to prevent damage to electronics
• Lubrication
  • Apply dry lubricant to moving parts like hinges and control linkages
  • Use silicone-based lubricants for motor bearings
  • Avoid over-lubrication, which can attract dirt
• Battery Care
  • Store LiPo batteries at about 50% charge for longevity
  • Regularly check for swelling or damage
  • Use a LiPo-safe bag for storage and charging
• Tightening and Realignment
  • Periodically check and tighten all screws and connections
  • Realign control surfaces if they've become misaligned during use

Common Repairs

• Cracked or Broken Parts
  • For small cracks, use CA glue (superglue) for a quick fix
  • For larger breaks, consider using epoxy for a stronger bond
  • In some cases, reprinting the damaged part may be necessary
• Delamination
  • If layers are separating, carefully apply thin CA glue between layers
  • Use a clamp or tape to hold layers together while the glue dries
• Strengthening Weak Points
  • Apply carbon fiber tape or thin carbon rods to reinforce high-stress areas
  • Use lightweight fiberglass cloth and resin for larger areas needing reinforcement
• Electronics Repairs
  • Resolder loose connections with a fine-tipped soldering iron
  • Replace damaged wires, ensuring proper gauge and insulation
  • If a component fails, replace it with an equivalent part
• Control Surface Repairs
  • Realign warped surfaces using gentle heat (hair dryer) and pressure
  • Replace damaged hinges with printed or commercial alternatives
  • For torn control surfaces, consider patching with thin plastic sheet and adhesive

Advanced Repair Techniques

• 3D Printing Repair Patches
  • Design and print custom patches for complex shapes or hard-to-find parts
  • Use the same material as the original part for consistency
• Foam Core Reinforcement
  • For larger repairs, consider inserting foam core material into hollow sections
  • This adds strength without significantly increasing weight
• Composite Repairs
  • For high-performance planes, learn to do basic composite repairs using fiberglass or carbon fiber
• Aerodynamic Touch-ups
  • After repairs, sand and smooth repaired areas to maintain aerodynamic properties
  • Apply a thin layer of filler and sand smooth for seamless repairs

FAQ

Can you 3D print an RC airplane?

Yes, 3D printing an RC airplane is possible and increasingly popular among hobbyists. With the right materials and design, 3D printed planes are lightweight, durable, and fully functional.

What is the best material for 3D printed RC planes?

Lightweight PLA (LW-PLA) is considered the best material due to its expanding properties, which create a lighter and more flight-efficient model. PETG is a good alternative for those seeking durability and flexibility.

Are 3D printed RC planes heavy?

Not necessarily. With the right settings and materials, 3D printed RC planes can be very lightweight. Using materials like LW-PLA and optimizing print settings like infill and wall thickness keeps the weight low.

Can planes be 3D printed?

Yes, planes can be 3D printed. Many designers create detailed, aerodynamic models that can be printed at home using a standard 3D printer. With proper assembly and the addition of electronics, these models can achieve impressive flight performance.