Creating each individual airplane model begins with the 3-D printing of each individual component. Using our knowledge of additive manufacturing, we determine the optimal orientation of each part to maximize their tensile strength.
After printing, each component must be coated with CA adhesive, which further increases the strength of each part. In addition, the adhesive also allows us to sand and refine aerodynamic surfaces using a fine grain, reducing the effects of drag due to friction. Some parts also require the insertion of threaded sleeves. These sleeves allow parts such as the outer wings and cockpit to be removable, so the internal mechanism, ailerons, and elevators can be adjusted post-assembly.
The elevators and ailerons function through the use of servo motors, rotating the elevators inphase and ailerons out of phase. It is important that we minimize the vibration of the control surfaces, so the servos are mounted in place using screws inserted into the threaded sleeves, while the rod spins freely and are supported by metal bearings.
After all of the parts have been fitted, we make sure to sand all imperfections or blemishes that may have formed throughout our process. At the same time, the internal mechanism also needs to be fitted during this time. Finally, we apply a few coats of black paint so that smoke testing in the wind tunnel will strongly contrast with the color of the planes and aid in our research, providing visual data for the experiment.