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Jan 17, 2015, 03:32 PM
A man without a plan
helifrek's Avatar
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3D Printed DJI Inspire discussion! (Update: Success at last!)


Welcome to the 3D printed DJI Inspire thread!

This thread is the place discuss everything about the 3D printed DJI Inspire designed by RCHobbysUK!

When this thread was originally posted I don't think a single 3D printed Inspire was flying. Now, with the help of the RCG community the design is successfully flying and being improved upon everyday!

I will try my best to keep this post updated with information, pictures, links, mods etc...... If you have something you think should be added or removed to the #1 post please PM me.

Thanks for visiting!

Here is a link to RCHobbysUK where you can buy the .stl files for the 3D printed Inspire

http://www.rchobbysuk.co.uk/store/p1...STL_FILES.html

Here is a link to their thingiverse page!
http://www.thingiverse.com/thing:593132


__________________________________________________ _______________________________________

My personal setup:

Frame: Printed on a Makergear M2 with PLA plastic, most parts are between 30% to 50% infill with the very small parts at 100% infill.

Motors: Multistar 4108-480Kv (hobbyking.com)
Battery: Multistar 5200Mah 6S 10C lipo (hobbyking.com)
Props: 13x5.5 carbon fiber (http://diyquadcopter.com/)
ESC: F-30A-HV from readytoflyquads.com (flashed with BLheli 13.0)
Arm Servo: sm-s4315r (can't remember where I bought it, they are pretty common though)
threaded rod to drive the arms: http://www.aliexpress.com/item/RepRa...849858328.html
The threaded rod requires some cutting, I redesigned the arm lifting bracket to fit the large brass nut. (check the rcgroups thread for files)
Carbon fiber tubes: 330x16mm from hobbyking.com
Flight Controller: Naza-M lite flashed with V2 Firmware

__________________________________________________ ________________________________________

Complete hardware list by Fragmaster!
https://www.rcgroups.com/forums/show...postcount=1022

__________________________________________________ ________________________________________



Frame Modifications and build tips

Here is a quick link to all of the files posted, I have included descriptions and listed the modified parts I am using to try and help out)
https://www.rcgroups.com/forums/thum...one&starter=no


There are several places where the frame has been improved upon by RCG members as well as RCHobbysUK, I will try to keep a list of these modifications here so that they are easy to find.

Links to modifications:


Improved lifting arms and framework strengthener (by Mr.RC-CAM)
https://www.rcgroups.com/forums/show...&postcount=157

ESC Box for mounting ESCs under the motors (by Mr.RC-CAM)
https://www.rcgroups.com/forums/showpost.php?p=30817760

Another ESC box (slightly smaller version with more holes for cooling) (by helifrek)
https://www.rcgroups.com/forums/showpost.php?p=30993972

LED Mounts (by Mr.RC-CAM)
https://www.rcgroups.com/forums/showpost.php?p=30836285

"Low Tech" Arm limit switch wiring solution (this is what I use and it works great!)
(Also by Mr.RC-CAM)
https://www.rcgroups.com/forums/showpost.php?p=30915205

Curved arm support (what I am using, they work great!) (by RTRyder)
https://www.rcgroups.com/forums/showpost.php?p=31011472

Servo cap for 1/4 threaded rod (by cozmogeek)
https://www.rcgroups.com/forums/showpost.php?p=31026861

Longer wheelbase frame (by nitewatchman)
https://www.rcgroups.com/forums/showpost.php?p=31032644

Extended RX shelf (by nitewatchman)
https://www.rcgroups.com/forums/showpost.php?p=31088493

Arm lifting bracket and servo adaptor for 8mm leadscrew with brass nut, this is what I use (by helifrek)
https://www.rcgroups.com/forums/showpost.php?p=31088493

Lower main frame with a hole for a flanged bearing (by xairflyer)
https://www.rcgroups.com/forums/showpost.php?p=31102463

Arm bushing to reduce slop in the T-Joints that attach the arms (I need these!) (by RTRyder)
https://www.rcgroups.com/forums/showpost.php?p=31142987

Other variations of Extended RX shelves (by cozmogeek)
https://www.rcgroups.com/forums/showpost.php?p=31222119

Modified rear bearing housing (this one was a big deal for me, this piece modifies the geometry of the pivot arms in relation to the main arms and allows the motors/props to stay more level during transition, I use this part)
(by my hero My.RC-CAM)
https://www.rcgroups.com/forums/showpost.php?p=31268845

Mount for Arduino (by Mr.RC-CAM)
https://www.rcgroups.com/forums/showpost.php?p=31277076

Simple GPS mount with template to cut the hole for the wire included.
(To Be Posted)




Build tips:
1. Do not use helicoils! instead use simple melt-in inserts (check out this post my Mr.RC-CAM
https://www.rcgroups.com/forums/show...&postcount=172

2. Curios about infill? I printed the majority of my parts at 30% infill, The very small parts like the servo strengthener are printed at 100% while the arms joints and being holders are printed at 50% infill. Most parts are printed with 2 to 3 shells for added strength.

3. Do you plan to use a Naza, possibly with CPPM? Use a gimbal channel from the naza with the gain set to 0% to control your arm lifting servo!

4. Make sure there is as little slop as possible in your arms, I used oversized 4mm hardware and re-drilled many of the holes to be a tighter fit with the 4mm hardware. This reduced the slop and wobble in my arms a lot!


Videos!

3D Printed Inspire (4 min 43 sec)

3D Printed DJI Inspire Arm transition (1 min 43 sec)

3d printed dji inspire quadcopter (7 min 43 sec)

3R printed DJI inspire maiden flight! (2 min 29 sec)

Dji inspire 3d printed (0 min 48 sec)

Part 1: 3D Printed "DJI Inspire One"-style DIY drone - Project kickoff (19 min 5 sec)

3D Printed "DJI Inspire One"-style Drone Part 2 - Printing all the parts (4 min 18 sec)

3D Printed "DJI Inspire One"-style DIY Quadcopter Part 3 - Construction (6 min 32 sec)

3D Printed DJI Inspire One style Quadcopter Part 4 - Electronics & Maiden Flight (18 min 44 sec)




RCG member complete or mostly complete builds!
Last edited by helifrek; May 11, 2015 at 09:22 AM.
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Jan 17, 2015, 04:11 PM
Registered User
This is awesome. Thanks for sharing all your work on this project.
Last edited by Tbock; May 01, 2015 at 12:43 AM.
Jan 17, 2015, 06:26 PM
3D Printing Junkie
dklassen's Avatar
Awesome! Just got all the files.
Jan 17, 2015, 07:39 PM
A man without a plan
helifrek's Avatar
Awesome dklassen!

I am lost in the sauce when it comes to motor and prop selection. Once I have those two figured out it should be simple to figure out what else to use!
I am eyeballing these motors right now

http://www.hobbyking.com/hobbyking/s...lt_by_DYS.html

or these

http://www.hobbyking.com/hobbyking/s...ong_Leads.html

what do you guys think?
Jan 18, 2015, 09:04 AM
Designer / Mechanical Engineer
Hi I'm the designer of the project over at RcHobbysUK thought I would pop along and say hi. I will help with any questions about the design.

I have also attached 2 photos of the stage that we are at with it. I was hoping that we would be in the test flight stages by now but we have not had enough free slots with our 3D printers to print the parts because of 3D print orders through our website.

if you have pictures you can share and tips for printing etc that would be great. Also any ideas for design changes or if you think something could be better please post.
Jan 18, 2015, 10:10 AM
Registered User
Blasphemor's Avatar
Quote:
Originally Posted by RcHobbysUK
Hi I'm the designer of the project over at RcHobbysUK thought I would pop along and say hi. I will help with any questions about the design.

I have also attached 2 photos of the stage that we are at with it. I was hoping that we would be in the test flight stages by now but we have not had enough free slots with our 3D printers to print the parts because of 3D print orders through our website.

if you have pictures you can share and tips for printing etc that would be great. Also any ideas for design changes or if you think something could be better please post.
Amazing.
Could you tell me how many abs need you to print ? 35 % fill?
How many hours need did you use to print?
Jan 18, 2015, 10:26 AM
Designer / Mechanical Engineer
We don't know exactly but at a guess I would say between 100-150 hours and roughly. It all depends on the layer height and speed of your printer.

Handy tip be careful when printing with ABS because it can shrink dramatically on cool down especially large parts like the Cowel and Main Frame. If you have manual control of your heatbed lower it in increments of 10 slowly over a period of time and keep enclosed to keep the heat in if you can.

A safe bet would be to use PLA for the large parts.

Also use as little infill as possible to keep the weight as low as possible. Not to much that your parts become week.

Set the external perimeters to 4 or 5 to keep the hole details strong for filling and tapping.

Some of the smaller parts were printed with as little as 10% in fill. I think we used 15 or 20% on the main frame and most of the parts in our picture.
Jan 18, 2015, 10:33 AM
Designer / Mechanical Engineer
Quote:
Originally Posted by helifrek
Awesome dklassen!

I am lost in the sauce when it comes to motor and prop selection. Once I have those two figured out it should be simple to figure out what else to use!
I am eyeballing these motors right now

http://www.hobbyking.com/hobbyking/s...lt_by_DYS.html

or these

http://www.hobbyking.com/hobbyking/s...ong_Leads.html

what do you guys think?
We actually based the design on the multistar 4108 480kv with 30a Simon K esc and 16x5.5 props. 3-4s 5000 Lipo should give around 2000 Kg of thrust which is more than enough.
Jan 18, 2015, 10:54 AM
A man without a plan
helifrek's Avatar
Welcome to the party RcHobbysUK!

Wow! I didn't realize 16" props would even fit on this thing! running a 4S pack might also be a little more cost effective as well. I am almost tempted to start printing this with my natural PLA and then just paint it. Unfortunately that would just add weight. So I will wait until I can order more plastic.
I have been thinking of designing a round Mobius enclosure that would look similar to the DJI camera on the Inspire. Already have a name for it, The MoBall!

I will to get some dimensions off of the DJI one first though.
Jan 18, 2015, 12:30 PM
Designer / Mechanical Engineer
Quote:
Originally Posted by helifrek
Welcome to the party RcHobbysUK!

Wow! I didn't realize 16" props would even fit on this thing! running a 4S pack might also be a little more cost effective as well. I am almost tempted to start printing this with my natural PLA and then just paint it. Unfortunately that would just add weight. So I will wait until I can order more plastic.
I have been thinking of designing a round Mobius enclosure that would look similar to the DJI camera on the Inspire. Already have a name for it, The MoBall!

I will to get some dimensions off of the DJI one first though.
We was planning on 13-14 inch props but 16 should work well. We will know more when we come to flight tests.

Love the idea of the moball.

We have designed a 3 axis gimbal for the DJI inspired using our MoPro design (Mobius to GoPro 3 conversion case) which can be found on our website under the STL downloads page in the Store.

The MoBall would be a really easy design and would probably take 4 or 5 hours to design, also it would be more compact and could be tucked up closer to the frame than a standard gimbal sits. Easy to hide the wires in side as well.
Jan 18, 2015, 02:36 PM
A man without a plan
helifrek's Avatar
You guys probably have a more professional design team It would probably take me a few days to design it! All I have is 123D design and I am not that great at it.
I do think it would be a really great addition to your inspire design though!
As soon as this F550 sells I will be able to order some of the hardware from you guys. can't wait!
Jan 18, 2015, 03:29 PM
Designer / Mechanical Engineer
I will have a look into it and see what we can come up with. I think it's a great idea and it would look great on the quad.
Jan 18, 2015, 03:47 PM
A man without a plan
helifrek's Avatar
What do you think about using some of these instead of the helicoils?

http://www.mcmaster.com/#standard-th...nserts/=vivy9z

Scroll down to the Twist-Resistant Press-Fit Inserts for Plastics

I don't think any special tools are required for it. It may be a slightly cheaper alternative.
Jan 18, 2015, 04:01 PM
Designer / Mechanical Engineer
Yeah or the press fit expansion inserts Slotted without Flange are even cheaper and in packets of 50. Think they would be the better choice.

http://www.mcmaster.com/#standard-th...nserts/=viw4ff
Jan 18, 2015, 04:33 PM
A man without a plan
helifrek's Avatar
Good eye, too bad they only have the metric ones in brass.


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