Manufacturing





Creating paper templates of airfoils is the first step in the wing manufactuing process.



The paper templates are used to trace an outline on a particle board sheet and cut to match the airfoil shape.



A hot nicrome wire, tensioned in a device called a Hot-wire Foam Cutter. Wooden airfoil templates are placed on either side of a foam blank and melted to shape.



Finished sections of Ballfoil, weight reliefed (MK IV+).

Prototypes





(MK 0) This is the first physical concept produced by the team, which was never tested.



(MK I) This is the first prototype the team tested. It featured a trycicle landing gear configuration, heavy rubber tires, and a 5000mAh battery. During testing, this iteration never became airborn as the center of gravity was in the wrong location, the plane was too heavy, and the elevator was undersized. Testing took place outdoors for this trial.



At this point in testing, snowy weather prevented the team from testing outdoors and operations continued indoors. Pine Patrol One MK II pictured above.



(MK II) The second iteration of the plane had a default angle of attack of 12.5 degrees, lighter foam tires, and a larger elevator. It was capable of getting airborn with some weighted payload.



(MK III) The third functioning prototype's primary changes included leading edge slats, a battery size reduction to 3000mAh, and 3D printed housing units for electronics.



(MK IV) The fourth iteration of the plane was built entirely from new parts, save the motor. Design changes included tapered wing tips, a new manufacturing method of all lifing surfaces, and the elevator and horizontal stabilizers integrated into a single part.

Mark V saw the limiting of the angular travel of the horizontal stabilizer, then Mark VI reverted the design back to using a fixed tail section with only an actuating elevator strip at the rear.

(MK VII) The seventh and current iteration of the design was constructed with the horizontal stabilizer fixed in a position pitched to 0 degrees angle of attack with respect to incoming flow. This allowed the front to lift off the ground earlier and yielded successful loaded test flights that satisfied all engineering requirements for competition.