Manufacturing Flags and Mitigation

Throughout the integration phase of our plane, a significant challenge arose concerning the wing mounts. Originally designed as separate mounts for the fuselage connector and wing connectors, the initial 3D-printed mounts, constructed from lightweight PLA, failed and snapped during 2G testing. To address this issue, we implemented a mitigation strategy by developing a new design that fused the fuselage and wing mounts, significantly enhancing robustness. Additionally, we opted for ABS material for the revised mounts, ensuring increased durability and resilience to the stresses encountered during testing. 

Regrettably, the revised design also proved unsuccessful during the 2G test. Faced with time constraints, our team engaged in a brainstorming session to devise an alternative solution. Through a thorough study of the problem, we identified that the excessive torque on the wing mount was primarily attributed to the wingspan. To address this challenge, we extended the wing supports and ingeniously utilized store-bought PVC to craft a new mount. This innovative solution proved effective and successfully resolved the issue, allowing us to move forward with the project.