Manufacturing Process

Continious Iteration Process

The team began the manufacturing process by beaking down the systems of the plane and deciding what materials to use. After some analysis the team decided to use Balsa wood as the main support structures with EVA foam as the main bluk of the plane

The team decided to utilize the NAU IDEA Lab, using the lazer cutter to cut the balsa wood into the wing ribs, the inner wing supports, and some portions of the fuselage. The other parts were cut by the team.

WING ASSEMBLY

The wings consist of 10 woodem frames, with one carbon rod running through the ribs with square supports holding the rod in place. The outer structure is made of 3mm Depron foam. It is all held together with hot glue.

ELECTRONICS

All of the electronics were purchased from Spektrum RC. The electronics consist of 4 micro metal gear servos, one brushless electric motor, ESC, reciever and controller.

FUSELAGE

The Fuselage is made of 6mm Depron foam, and 1mm balsa wood. Held together with hot glue. At the center of the fuselage is the container for the electronics. The battery, ESC, and servo wires lie within and are held in place by velcro. The motor is mounted outside the fuselage and is connected by four 1/8th inch screws and hot glue.

CURRENT ASSEMBLY

The connecting structure is made out of hollow 1 inch aluminum tube, that is connected to the fuselag with L brackets and hot glue. The servo wires run through the tube and through the foam to the ailerons. The tail is made of 6 mm Depron foam, with thin wodden strucutres inside to add support. The landing gear is borrowed from the previous SAE Aero groups.

FINAL ASSEMBLY

This is the final design from the iteration process. The extended fuselage is made of a square 3mm Depron foam tube. Within the tube are several balsa wood and Depron foam ribs to add support. The Servo wires run through the tube to the tail and rudder. The landing gear is made of a thin steel bent into a zigzag pattern. This was done in order to dispurse the forces acting on it. In order to move the center of gravity 2.5 lbs of weight were added to the nose of the plane to get an appropriate center of gravity.