Designing and Manufacturing

Design:

Following the completion of theoretical design, our focus transitioned to the meticulous modeling of the plane. The CAD of the aircraft underwent significant evolution over time, marked by continuous adjustments and improvements to enhance the overall system. The initial concept was sketched using OpenVSP, and subsequent, more detailed iterations were crafted using SolidWorks. The visual progression of the plane, evident in the images, highlights the iterative development process, with the most notable change being the refinement to the fuselage design. 

Manufacturing: 

The fuselage of the plane was constructed using a single carbon fiber rod, initially designed to be square but later adapted due to budgetary considerations. Lightweight PLA 3D-printed mounts were utilized to connect the fuselage to the wing, tail, and motor.

For the wings and tail, a combination of balsa and Sande plywood ribs was employed. After assembling the initial skeleton of the plane, we employed a polyethylene shrink wrap to form the outer skin. This process involved taping and stapling the wrap around the wing and then utilizing a heat gun for shaping. To set the shape immediately, a hairdryer on a cool setting was applied, ensuring a secure and well-defined form for the aircraft's wings.