Building my own Multicopter

[Bruno28]

Hey everyone, ive started designing my own frame, which looks similar to the Cinestar, but for now Im also learning to use this new CAD program.
It would be good if people suggested ideas to put into this design.
The first design is just practice and nothing like the final build will be.

I still need to design the fixtures, motor mount, landing gear and some other stuff.

 

[ewr]

Not sure if those rectangle openings above each arm are already for what I will suggest...but ever since I've started cutting my own CF I've always measured my ESC's and cut exact fitting holes for them, and cutting CF plates similar to the battery plates, which go underneath the ESC's and bolt to the top plate via Ti spacers. The ESC mounting and wiring, at least to me, is always the part that makes a MR either look messy or clean and neat. I've seen some awesome platforms made to look horrible with the ESC's mounted crooked/zip tied or taped on/wires everywhere. This is obviously a more cosmetic rather than functional issue (until ones falls off or becomes unplugged!) but if your doing a ground up scratch build, something to consider. Also, mounting holes for whatever power distribution you select will make that easier too.

 

[Bruno28]

Not sure if those rectangle openings above each arm are already for what I will suggest...but ever since I've started cutting my own CF I've always measured my ESC's and cut exact fitting holes for them, and cutting CF plates similar to the battery plates, which go underneath the ESC's and bolt to the top plate via Ti spacers. The ESC mounting and wiring, at least to me, is always the part that makes a MR either look messy or clean and neat. I've seen some awesome platforms made to look horrible with the ESC's mounted crooked/zip tied or taped on/wires everywhere. This is obviously a more cosmetic rather than functional issue (until ones falls off or becomes unplugged!) but if your doing a ground up scratch build, something to consider. Also, mounting holes for whatever power distribution you select will make that easier too.

The rectangles are so the the frame is lightest as possible. And from that cutout, i can produce other small parts.

Ok good thinking, so design something that helps the ESC wireing be organized.
What power distribution do you consider to be the best?

 

[PeterLester]

Go with the carbon fiber tubes but start out with fiberglass reinforced plywood or G10 plate until your prototype is revised to a rollout stage.... Once the rollout units are flight proven to your entire satisfaction, move carefully up to DragonPlate materials such as carbon fiber laminated plywood etc. Solid carbon fiber plate provides no additional advantage over cf reinforced plywood or birchwood and cost far too much. The reinforced wood from Dragon plate are also much easier to cut. Solid CF plate is one of the worst possible materials to mill and you will be replacing dulled bits hourly. Both G10 plate and carbon fiber dust are very significant health hazards....... no-one fully understands yet just how dangerous CF dust can be..... might be as bad as asbestos.

The rectangles are so the the frame is lightest as possible. And from that cutout, i can produce other small parts.

Ok good thinking, so design something that helps the ESC wireing be organized.
What power distribution do you consider to be the best?

 

[Bruno28]

Go with the carbon fiber tubes but start out with fiberglass reinforced plywood or G10 plate until your prototype is revised to a rollout stage.... Once the rollout units are flight proven to your entire satisfaction, move carefully up to DragonPlate materials such as carbon fiber laminated plywood etc. Solid carbon fiber plate provides no additional advantage over cf reinforced plywood or birchwood and cost far too much. The reinforced wood from Dragon plate are also much easier to cut. Solid CF plate is one of the worst possible materials to mill and you will be replacing dulled bits hourly. Both G10 plate and carbon fiber dust are very significant health hazards....... no-one fully understands yet just how dangerous CF dust can be..... might be as bad as asbestos.

Ok good idea of using G10 for design price cost cut.
I would get the carbon cut at the same place that they provide. So they know how to cut it without leaving dust around.

 

[kloner]

You have an aweful lot missing from them center plates. imo too much, anything beyond 2814 with a dslr is gonna see alot of flex. that is the cs8 weakness from what i've seen

 

[Bruno28]

You have an aweful lot missing from them center plates. imo too much, anything beyond 2814 with a dslr is gonna see alot of flex. that is the cs8 weakness from what i've seen

It was just a test design. I did another one more beefy. But still only designing different types.

 

[Bruno28]

Designed the motor mounts
The groove inside is so that the clamps are around an o-ring, this will help absorb any motor/prop vibrations.
Hole diameter is for 25mm diameter tube

 

[Bruno28]

Assembled with frame design 1 and motor plate

 

[Bruno28]

could one of the moderators move this post to "Multi-Rotor Build Threads" please

 

[Bruno28]

Here is my latest frame design. Its a Octa.
Those are 15'' props.
View attachment 12840View attachment 12841View attachment 12842View attachment 12843View attachment 12844

 

[Bruno28]

The same Octa Frame can be used to build a Quad, or a Coax Quad.
The arms on the coax quad is 350mm length, While the arms on the Octa are 450mm length.
View attachment 12846View attachment 12847View attachment 12848View attachment 12849View attachment 12850

 

[Bruno28]

This seems to be my closes design to the actual end result.
Included a FC table and ESC mountings with slots to help cooling. Holes for the ESC cables to be neatly connected to the inside of the carbon arms.
Next step is to solve putting a power distribution board.
View attachment 13141View attachment 13142View attachment 13143View attachment 13144View attachment 13145

 

[Bruno28]

Here is a test of Laser cutting a prototype before i do a carbon fibre cut.
The prototype is 1/2.5 scale. Came out very good.

Here is the video of the cut being made. Its quite interesting.

View attachment 13691

 

[PeterLester]

Very well done..... Looking forward to seeing the carbon fiber cutting with laser.

 

[Bruno28]

Very well done..... Looking forward to seeing the carbon fiber cutting with laser.

Thank you my friend.
Unfortunately laser will not cut carbon fibre well. Because carbon fibre is a fabric with resin, if you use a laser that is too powerful beam, it melts the resin and if its a weak laser beam, the carbon doesn't cut all way and leaves sharp edges that need sanding. The laser was just to see what the prototype would look like in real life, before a full carbon fibre (more expensive version) is made.
SO the Carbon fibre will be CNC, which I will be doing very soon as i found a provider of carbon fibre and cnc machining.

This will be a big octococopter/quadcopter, from drawing it will have a little over 1000mm span from arm to arm.
It can used 14x5 props no problems

 

[gtranquilla]

Bruno..... if you dig through the following all the way to their online pricing you will see that they charge quite a bit more for CNC machining of carbon fiber plate. This is because CF plate is considered one of the most difficult of all materials to work with.... dulling and burning out most bits and tools very quickly. The best solution is a milling machine with fluted bits made of ???? can't remember.... http://www.emachineshop.com/ But one of the best ways to make the cutting easier is to use the birch or plywood carbon fiber reinforced plate sold by dragonplate and others...... I have had great success making my own fiberglass and carbon fiber plate using a vacuum bagging system. two layers of cf on both sides of aircraft grade thin plywood etc. http://dragonplate.com/ecart/categories.asp?cID=3

 

[mtec]

hi bruno, nice setup, whats your stand, the copter is flying now !?

maybe its possible tu buy your plan for my copter?

thx for answer.

marcell

 

[Bruno28]

Bruno..... if you dig through the following all the way to their online pricing you will see that they charge quite a bit more for CNC machining of carbon fiber plate. This is because CF plate is considered one of the most difficult of all materials to work with.... dulling and burning out most bits and tools very quickly. The best solution is a milling machine with fluted bits made of ???? can't remember.... http://www.emachineshop.com/ But one of the best ways to make the cutting easier is to use the birch or plywood carbon fiber reinforced plate sold by dragonplate and others...... I have had great success making my own fiberglass and carbon fiber plate using a vacuum bagging system. two layers of cf on both sides of aircraft grade thin plywood etc. http://dragonplate.com/ecart/categories.asp?cID=3

thanks for the hint.
Apparently the company Im using to manufacture prototype 1 are able to make a good outcome. Im still waiting for the parts to arrive and inspect for its quality.

 

[Bruno28]

hi bruno, nice setup, whats your stand, the copter is flying now !?

maybe its possible tu buy your plan for my copter?

thx for answer.

marcell

Its not flying yet! Ive got most of the parts, just waiting on the main frame to be produced and cut out.
Before any sale i would like to do some testing, so I can eliminate any possible problems. I think I will have it up and flying in a month time.
I have a friend that wants to do a video footage with a big setup for a DSLR camera, so ill have to complete the build soon.
I will keep you posted on the results and pictures of build on this Thread, so you can follow and see if you like it.
Are you interested in the physical final product or CAD drawing?