Kaiju Quadcopter
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Final Design: The final design was a mixture of our preliminary designs that was then further modified and improved. It consists of four different pieces. Those pieces are the battery casing, shell, arm top and the arm bottom (a flat plate cut to size). The design is lightweight, impact resistant, and allows for easy access to the internal components for modification and repairs.

 

Component Installation: There are multiple component installation steps for the Kaiju. The internal components consist of the motor, battery, electronic speed control, arduino, and the frame that holds everything together in place. The outside components consist of the propellers.

Final Design

 

Tooling and Fabrication: The tooling was made of modeling board and was CNC Machined from Solidworks drawings. The tools required finishing, which consisted of alternating between touching up with Bondo and sanding, to achieve a smooth surface. Before layup, the tools received several layers of wax and a layer of polyvinyl acetate (PVA). Infusion was used to create the parts. Infusion is a process where fabric is place in a mold and permeated with a liquid resin under vacuum to draw the resin through the fabric layers. West System Epoxy 105/206 resin/hardener with three layers of glass fiber and one layer of carbon fiber for aesthetics. The arms were assembled using Loctite Epoxy and the shell was assembled using fasteners.

Flexure Testing and Impact testing were conducted on our part. The flexure test was conducted on the three layers of glass fiber with one layer of carbon fiber. Multiple specimens were utilized for the sample, which was then compared to a sample that had been submerged in water for 24 hours. The samples were submerged to simulate long term exposure to outdoor moisture from varying weather conditions. The results showed only a small decrease in properties in the sample submerged in water. The assembled quadcopter, not including the electrical components, was dropped from three increasing heights, ending at 25 feet. The quadcopter sustained no damage except that some of the epoxy on the arm assemblies came off.