Project: Mass-Producible Modular Glider Design
Target Quantity: 50 units
PROJECT OVERVIEW
This project aims to design and manufacture 50 modular glider aircraft using available manufacturing processes. The design emphasizes modularity, repeatability, and manufacturability within facility constraints.
Design Philosophy:
- Modular construction enabling component replacement
- Snap-fit and mechanical fastening methods where feasible
- Manufacturing process selection based on part geometry and production volume
- Design flexibility to accommodate process-specific constraints
MANUFACTURING APPROACH
Process Selection Criteria
Manufacturing processes will be selected based on:
- Part geometry and complexity
- Material requirements (rigidity, flexibility, impact resistance)
- Production volume (50 units)
- Available equipment capabilities
- Tolerance requirements
Anticipated Manufacturing Methods
| Process | Anticipated Applications | Equipment |
|---|---|---|
| Injection Molding | Small rigid components (nose, tail parts, mounting hardware) | PIM Shooter 300A (2 in³ shot limit) |
| Thermoforming | Large thin-wall components (fuselage body) | Formech 450DT |
| Laser Cutting | Flat structural elements (spars, ribs, reinforcements) | EPILOG HELIX |
| 3D Printing | Complex geometries, prototypes, low-volume parts | Bamboo H2D (FDM) |
Note: Final process assignment will be determined during detailed design phase based on part-specific requirements.
COMPONENT ARCHITECTURE
Major Assemblies (Preliminary)
Airframe Components:
- Nose section with weight pocket
- Wing assembly (modular sections)
- Fuselage body
- Tail assembly (vertical and horizontal stabilizers)
- Landing gear/skid
Integration Features:
- Mechanical fastening points
- Snap-fit interfaces where appropriate
- Control surface mounting provisions
- Ballast adjustment mechanism
Assembly Strategy
- Primary: Mechanical fasteners for structural joints
- Secondary: Snap-fit connections for non-structural assembly
- Tertiary: Adhesive bonding where disassembly is not required
BILL OF MATERIALS
Non-Standard Materials (Required Purchase)
| Item | Specification | Quantity | Unit Cost | Total Cost | Source |
|---|---|---|---|---|---|
| Control Linkages | 1.5mm carbon fiber rod, 200mm length | 100 pcs | $0.57 | $57.00 | Ebay |
| Linkage Hardware | Micro swivels for control connections | 200 pcs | $0.078 | $15.98 | Amazon - Micro Swivels |
| Ballast Material | Lead shot, 1 lb bag | 2 bags | $12.99 | $25.98 | Amazon - Lead Shot |
| Cyanoacrylate Adhesive | Medium viscosity, 2 oz bottle | 10 bottles | $6.00 | $60.00 | Amazon - CA Glue |
Non-Standard Materials Subtotal: $158.96
Cost per Glider (Non-Standard Materials Only): $3.18
DESIGN CONSIDERATIONS
Joint Design Principles
Snap-Fit Connections:
- Design with appropriate draft angles and retention features
- Include tolerance for thermal expansion/contraction
- Consider assembly/disassembly cycles in retention design
- Test prototypes for 20+ assembly cycles
Mechanical Fasteners:
- Use for primary structural connections
- Design boss geometry for adequate thread engagement
- Include provisions for disassembly/maintenance
Living Hinges:
- Material selection: PP or PETG (fatigue resistant)
- Hinge thickness: 0.010”-0.020” typical
- Include stress relief features at hinge terminations
Manufacturing Constraints
Injection Molding:
- 2 in³ shot size maximum
- Wall thickness: 0.060”-0.120” nominal
Thermoforming:
- Include air relief holes in tooling design
Laser Cutting:
- Kerf compensation: 0.005”-0.010”
QUALITY CONTROL & TESTING
Dimensional Verification
- Measure critical dimensions on first article from each process
- Verify snap-fit function before production run
- Check control surface deflection angles
- Confirm center of gravity location
Assembly Testing
- Verify assembly sequence and time requirements
- Test snap-fit durability (minimum 20 cycles)
- Confirm all fasteners seat properly
- Validate ballast adjustments
Flight Testing Protocol
- Ground test: control surface movement, structural integrity
- Hand-launch glide test: basic stability assessment
- High-launch test: glide ratio measurement, trim adjustment
- Durability test: landing impact resistance
NEXT STEPS
- Complete detailed CAD design for all components
- Finalize material selection based on specific part requirements
- Design and fabricate tooling (injection molds, thermoform molds)
- Manufacture prototype (1-2 units) for fit and function testing
- Conduct flight testing and iterate design as needed
- Begin production run after prototype validation
APPENDICES
Standard Lab Materials (Not Included in BOM)
The following items are assumed to be available as standard lab supplies:
- Sandpaper (various grits)
- Masking tape
- Safety equipment (gloves, eye protection)
- Cleaning solvents
- Measuring tools (calipers, micrometers)
- Hand tools (screwdrivers, pliers, cutting tools)
Equipment Requirements
| Equipment | Use | Notes |
|---|---|---|
| PIM Shooter 300A | Injection molding | 2 in³ shot capacity |
| Formech 450DT | Thermoforming | 18” × 24” forming area |
| EPILOG HELIX | Laser cutting | 50W CO₂, 24” × 36” bed |
| Bamboo H2D | 3D printing | FDM, 250mm³ build volume |
| CNC Mill | Mold fabrication | For tooling production |
Abbreviations
- ABS = Acrylonitrile Butadiene Styrene
- BOM = Bill of Materials
- CA = Cyanoacrylate
- CAD = Computer-Aided Design
- CG = Center of Gravity
- CNC = Computer Numerical Control
- FDM = Fused Deposition Modeling
- PETG = Polyethylene Terephthalate Glycol
- PLA = Polylactic Acid
- PP = Polypropylene
License: Creative Commons BY-SA 4.0 (hardware designs) / MIT (software/documentation)