254 lines
7.3 KiB
Markdown
254 lines
7.3 KiB
Markdown
# SkyLogic AeroAlign - 3D Printable Parts
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**Status**: active documentation for AeroAlign plus planned CoG fixtures
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**Design Tool**: FreeCAD 0.20+
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**Export Format**: STL
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---
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## Overview
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This directory covers both halves of the project:
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- AeroAlign IMU housings and clips
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- future CoG scale fixtures and support cradles
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All parts should stay printable on common 200mm-class FDM printers.
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---
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## Part List
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### Sensor Housing (Required)
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1. **sensor_housing_top.stl**
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- Dimensions: 38mm × 28mm × 8mm
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- Features: Clip-on IMU holder, LED window, USB-C port access
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- Material: PLA or PETG
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- Infill: 20% cubic
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- Support: None required (designed for support-free printing)
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- Print time: ~45 minutes
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2. **sensor_housing_bottom.stl**
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- Dimensions: 38mm × 28mm × 10mm
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- Features: Battery compartment (400mAh LiPo), 4× M2 screw holes
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- Material: PLA or PETG
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- Infill: 20% cubic
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- Support: Minimal (<10% volume)
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- Print time: ~1 hour
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### Control Surface Clips (Choose appropriate size)
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3. **clip_3mm.stl**
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- For 3mm thick control surfaces (small foam ailerons)
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- Spring clip design, PETG recommended for flexibility
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- Rubber pad inserts: 6mm diameter × 1mm thick
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4. **clip_5mm.stl**
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- For 5mm thick control surfaces (standard balsa elevators)
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- Most common size for RC models
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5. **clip_8mm.stl**
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- For 8mm thick control surfaces (large rudders, thicker wings)
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- Reinforced jaw design
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### Multi-Sensor Expansion / Future AeroAlign
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6. **wing_surface_mount_adjustable.stl**
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- 3-point contact clip for wing root attachment
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- Adjustable height: 10-20mm
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- Dimensions: 120mm × 80mm × 35mm
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- Rubber pad inserts: 6× pads (front, mid, rear)
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7. **wing_surface_mount_50mm.stl**, **wing_surface_mount_100mm.stl**, **wing_surface_mount_150mm.stl**
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- Fixed-size wing clips for 50mm, 100mm, 150mm chord wings
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- Faster to print than adjustable version
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8. **control_surface_clip_springloaded_3mm.stl**
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- Spring-loaded clip (PETG material required)
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- Grips trailing edge securely without adhesive
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9. **hinge_line_mount_universal.stl**
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- L-shaped bracket for hinge line attachment
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- Measures differential directly at pivot point
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10. **magnetic_mount_base.stl**
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- Self-adhesive metal plate (3M VHB backing)
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- Dimensions: 20mm × 10mm × 1mm
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- Pairs with sensor_housing_magnetic_top.stl
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11. **sensor_housing_magnetic_top.stl**
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- Variant of sensor_housing_top.stl with magnet pockets
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- 2× N52 neodymium magnets (10mm diameter × 2mm thick)
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### CoG Scale Fixtures (Planned)
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12. **cog_baseplate.stl**
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- Flat base aligning front and rear supports
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- Carries the support spacing reference
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13. **cog_support_front.stl**
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- Front cradle above load cell #1
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- Should include anti-slip contact pad area
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14. **cog_support_rear.stl**
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- Rear cradle above load cell #2
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- Matching geometry for repeatable support spacing
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15. **cog_hx711_mount.stl**
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- Protected electronics bracket for HX711 boards
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- Cable strain relief recommended
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---
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## Print Settings
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### Recommended Settings (FDM)
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| Parameter | PLA (Housing) | PETG (Clips) | TPU (Optional) |
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|-----------|---------------|--------------|----------------|
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| Layer Height | 0.2mm | 0.2mm | 0.25mm |
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| Infill | 20% cubic | 30% grid | 40% gyroid |
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| Wall Count | 3 | 4 | 3 |
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| Top/Bottom Layers | 4 | 5 | 4 |
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| Print Speed | 60mm/s | 45mm/s | 30mm/s |
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| Nozzle Temp | 205°C | 235°C | 215°C |
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| Bed Temp | 60°C | 80°C | 60°C |
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| Support | None/Tree | Tree | None |
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### Tolerances
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- Screw holes: 2.2mm diameter (for M2 screws, accounts for ±0.2mm print variance)
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- Clip jaw opening: ±0.3mm clearance for control surfaces
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- Snap-fit features: 0.5mm interference for secure assembly
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---
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## Assembly Notes
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### Sensor Housing Assembly
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1. **Insert Electronics**:
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- ESP32-C3 DevKit in top shell
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- MPU6050 IMU aligned with housing center
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- LiPo battery in bottom shell compartment
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2. **Close Housing**:
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- Align top and bottom shells
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- Insert 4× M2×6mm screws through bottom, into top
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- Tighten until snug (do not overtighten, plastic may crack)
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3. **Attach Clip**:
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- Choose appropriate clip size (3mm, 5mm, or 8mm)
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- Slide clip onto housing rails
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- Apply rubber pads to clip jaws (prevent surface scratches)
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### Magnetic Mount Assembly (Multi-Sensor)
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1. **Prepare Base Plate**:
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- Clean model surface with isopropyl alcohol
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- Apply 3M VHB tape to magnetic_mount_base.stl
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- Press firmly onto wing/elevator (wait 24h for full adhesion)
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2. **Install Magnets**:
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- Insert 2× N52 magnets into sensor_housing_magnetic_top.stl pockets
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- Ensure correct polarity (N-S attracts base plate magnets)
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- Secure with CA glue if loose
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3. **Attach Sensor**:
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- Snap sensor housing onto magnetic base (2-second operation)
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- Magnets hold ~500g force (sufficient for workshop use)
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---
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## Design Files (Source)
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**FreeCAD Project Files** (for customization):
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- `sensor_housing.FCStd` - Parametric housing design
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- `clips_library.FCStd` - Clip variants (3mm, 5mm, 8mm)
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- `wing_mounts.FCStd` - Multi-sensor expansion mounts
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**To Export STL**:
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1. Open `.FCStd` file in FreeCAD
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2. Select part in tree view
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3. File → Export → Mesh Formats (.stl)
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4. Settings: Deviation 0.1mm, Max mesh angle 20°
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---
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## Testing and Validation
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### Validation Tasks
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- [ ] T058: Print sensor housing on Ender 3 (verify fit and tolerance)
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- [ ] T059: Test print on Prusa Mini and Bambu Lab P1P (cross-printer compatibility)
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- [ ] T060: Create assembly guide with photos
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- [ ] T061: Document print settings for all STL files
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- [ ] T062: Weigh assembled nodes (verify <25g per node)
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- [ ] Validate CoG support rigidity under expected aircraft weights
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- [ ] Validate repeatable support spacing for CoG calculation
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### Durability Testing
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- [ ] T080: Drop test from 1 meter onto hard surface (10 times)
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- [ ] T123: Test specialized mounts on RC model (foam wing, balsa surfaces)
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---
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## Material Costs
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- PLA filament: ~20g per sensor housing = $0.40 @ $20/kg
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- PETG filament: ~10g for 6 clips = $0.25 @ $25/kg
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- **Total material cost per system**: $0.65 (negligible)
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---
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## Printer Compatibility
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Tested on:
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- [ ] Creality Ender 3 V2 ($200, 220mm build volume)
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- [ ] Prusa Mini+ ($400, 180mm build volume)
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- [ ] Bambu Lab P1P ($500, 256mm build volume)
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- [ ] Anycubic Kobra ($250, 220mm build volume)
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**Minimum Requirements**:
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- Build volume: 200mm × 200mm × 200mm
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- Layer height: 0.2mm capability
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- Filament: PLA or PETG compatible
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---
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## Alternative: 3D Printing Services
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If you don't own a 3D printer:
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- **3D Hubs / Craftcloud**: Upload STL, get quotes from local printers ($10-20 per set)
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- **Shapeways**: Online 3D printing service (higher cost, premium materials)
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- **Local Makerspaces**: Many libraries and hackerspaces offer 3D printing for members
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---
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## License
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Hardware designs (STL files, FreeCAD sources) are licensed under:
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**Creative Commons BY-SA 4.0**
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You are free to:
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- Share: Copy and redistribute in any medium or format
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- Adapt: Remix, transform, and build upon the material
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Under the following terms:
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- Attribution: Give appropriate credit to SkyLogic AeroAlign project
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- ShareAlike: Distribute derivatives under same license
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---
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## Roadmap
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**Current**: IMU housing and clips
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**Next**: CoG baseplate and load-cell support fixtures
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**Later**: integrated mixed-tool workshop kit
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---
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*SkyLogic AeroAlign - Precision Grounded.*
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