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Skynet-V1 a.k.a. “The Red Baron” People Responsible: Wings – Erik, Peter, Ian, Akshay; Fuselage – Erik, Peter, Ian, Akshay, Brandon; Motor and Control Surfaces – Erik, Peter, Ian, Akshay, Brandon; Pilot – Emilio & Brandon Wings Foam cutting our wings was a relatively easily and fast process.

The GMFC application made choosing wing profiles and cutting wings very simple. However, we did discover several limitations when using the EPS (expanded polystyrene) foam. Because our wing profile is rather thin (9%), the cut EPS foam wings were very flexible and had little torsional rigidity. We hand-cut the wings at the quarter-chord and glued in a 1/16” balsa wood spar. This resulted in a significantly stiffer wing.

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Limitations of hot-wire foam cutting were evident in areas where the wire moved slowly or rotated about a fixed point. These areas exhibited significant foam shrinkage and a resulting distortion in wing shape.

Unfortunately, this was most obvious in the leading edge of our wings near the tips. It is quite possible that the resulting airfoil was significantly different from our design intent. We believe that using a stiffer foam – such as EPO (expanded polyolefin as used in the Bixler2) or Rigid EPS (rigid extruded polystyrene “blue foam”) – would yield a better result, more accurate wing shape and smoother surface finish. Smooth Foam Cut Due to the relatively rough finish of the hot-wire-cut white beaded EPS foam, we opted to cover the wings in monocoat film to both smooth the wing surfaces and to potentially add rigidity to the wing.

We also opted to “dope” the trailing edges of the cut foam with glue, hoping to add rigidity with little weight. The resulting wings were significantly heavier than we anticipated – mostly due to the glue. On one wing, we also experimented with adding a layer of tissue paper to the glued trailing edge – while this contributed significantly to stiffening the trailing edge, applying the tissue paper required more glue which likely cost an extra 10g of weight in the right wing. In the future, if we use wire-cut foam, we will likely cut out sections of the foam to lighten the structure, still use a balsa or carbon fiber ribbon as a spar, replace the trailing edge with a narrow strip of balsa and still use monocoat film for the surface. An additional significant concern is the potential for the shrinking monocoat film to impart shape-changing forces to the foam wing. Because there is little structural resistance from the foam, the shrinking film imparted a tip-downward twist to the right wing.

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This aerodynamic distortion, combined with a heavier wing from experimental construction techniques, will likely cause undesired flight characteristics and must be avoided in future construction – particularly in the wings. Attaching wings to the fuselage Fuselage Initially, we decided to cut the fuselage – as an airfoil shape – using the hot-wire / foam method.

This resulted in a useable shape, but presented signficant challenges in construction as the foam did not present a rigid structure for attaching wings. Requiring wide sections of foam for structural strength also threatened to make the fuselage section quite large in order to provide adequate payload volume for electronics and batteries. After deciding we did not like the foam fuselage, we opted to laser-cut a set of balsa ribs (2) and bulkheads (4) as our fuselage. The resulting fuselage was very easy to assemble, yielded very precise shape and contributed to some overconfidence in construction. The build team discovered that the fuselage had been glued too early, not having made provisions for wiring wing servos (using the Y-cable, the two wings were now attached to each other and difficult to wire).