We develop a scalable RC helicopter platform whose structure and drive system is consistently designed for additive manufacturing, service-friendliness and high-speed drivetrains. Key features include a printed lightweight spaceframe, variable rear-wheel drive transmission, a four-blade tail rotor concept and material-optimized bearing pairings for high long-lasting.
An engineering builder
Short iteration cycles, spare parts availability on demand and resilient components determine the concept. Components can be exchanged in a low-tool manner, translations can be adapted to new setups and the structure can be reproduced using the FDM process.
The core: a resilient spaceframe
The fuselage is designed as a spaceframe: high stiffness with low weight and at the same time easily accessible service points. The standard material is PC-CF, depending on the application; PPS-CF or PA12-CF can be used for special temperature, chemical or vibration requirements.
Rear concept: four-leaf and variable translation
The four-blade tail rotor works with an interchangeable external transmission stage. Sliding and sintering bearings reduce friction and simplify maintenance. The ratio, number of sheets and bearing strategy are treated as configurable parameters so that rotational speed, thrust and running culture can be measurably tuned.
Drive and safety
- Main rotor drive with defined reduction and reproducible torque window.
- Actively cooled planetary gearbox for thermally stable running.
- Structural reserves on the rotor head and configurable two-, three- or four-leaf version.
- Separate line paths for power and signal as well as easily accessible service points.
Modularity in practice
The front section takes up battery carriages, avionics, telemetry or sensors. Displaceable carriages facilitate center of gravity management, defined airways separate hot and cold areas, and pluggable modules shorten conversion and repair times. Adapters, holders and inserts can be rebuilt project-specifically.
Learning from the first rounds
The rear shaft proved to be an important influence on torsion and reaction behavior. Material selection, clamping block connection and controlled twisting improve efficiency and durability. Also oblique toothing and a suitable temperature window of the plastics used contribute significantly to the running culture.
For whom the project is intended
The platform is aimed at prototype builders, test pilots and material enthusiasts who want to tune their system by load profile, speed windows and operating environment. CAD adaptation, print data, material selection and manufactured components can be designed together for specific projects.