Tom Stanton Develops 3D Printed Windup Plane Capable of 45-Second Flight on Four-Second Charge

Tom Stanton Develops 3D Printed Windup Plane

British engineer Tom Stanton has created a 15.6-gram 3D printed aircraft powered by a single 10 farad supercapacitor. This innovative design features a hand crank charging system that allows for a flight duration of 45 seconds after approximately four seconds of winding. Stanton documented the project in a video on his YouTube channel, which showcases a modern take on the classic rubber band-powered toy aircraft through the use of additive manufacturing and contemporary energy storage solutions.

Design and Construction Details

Stanton’s build replaces traditional balsa wood with 3D printed ribs on tissue paper. The wing structure is printed directly onto the tissue paper, which is secured to a magnetic build plate, resulting in a skeletonized rib pattern that bonds to the covering in a single operation. A carbon fiber rod serves as the fuselage spine, with friction-fit printed components holding the wing and tail together. The initial glider prototype weighed 3.8 grams and outperformed a folded paper airplane in side-by-side tests.

Powered Version Specifications

The powered version of the aircraft utilizes a brushed micro motor commonly found in small toy quadcopters. Due to the supercapacitor’s voltage limit of 2.7 volts, which is lower than that of a single lithium battery cell, Stanton opted for a slightly larger propeller designed for lower RPM efficiency. An analog voltmeter is installed between the hand crank generator and the capacitor to prevent overcharging, which could damage the cell.

Supercapacitor Selection Process

Stanton’s choice of supercapacitor was based on energy density per gram. He analyzed various single-cell supercapacitors and identified a critical point: below the 10 farad mark, packaging weight becomes a significant factor, leading to a decrease in energy density. Although a 100 farad cell offers approximately six times the energy density of a 1 farad cell, it weighs 20 grams, which is too heavy for the airframe. The 10 farad unit, weighing around 3 grams, provided an efficient balance.

Flight Performance and Environmental Considerations

The design of the wing was influenced by its aspect ratio and torsional stiffness. An early prototype with a long wing experienced catastrophic flutter during flight, prompting a redesign. The revised wing features a shorter chord and higher aspect ratio, which moves the center of pressure closer to the structural center, reducing twisting moments while maintaining span efficiency against induced drag.

However, tissue paper proved to be a limitation in colder conditions. Flights conducted at -2°C (28°F) succeeded initially, but subsequent attempts were hindered by moisture absorption, which compromised the wing’s structural integrity. Stanton noted that this construction technique is likely more suitable for calm summer evenings or indoor flying.

Implications for Drone Research

Supercapacitors are already utilized in commercial unmanned aviation, primarily as a supplementary energy source. Research on hybrid propulsion systems has demonstrated their effectiveness in managing peak current demands in hydrogen fuel cell drones. The challenges Stanton addresses are similar to those faced by engineers in the defense drone sector.

The advancements in 3D printed airframes are also noteworthy. Previous coverage has highlighted various applications, including the 3D printed Stallion fixed-wing platform and the Lace foldable research drone. Stanton’s project, while on a smaller scale, introduces a fabrication technique that could benefit makers aiming for sub-20 gram airframe weights.

Conclusion

Stanton’s project highlights the ongoing challenges in unmanned aviation, particularly regarding flight time. The balance between energy density and weight remains a critical issue for manufacturers. His approach simplifies the problem to its core components: a 10 farad capacitor, a 3-gram payload, and a wing capable of withstanding aerodynamic loads.

The potential for quick turnaround inspection drones and disposable reconnaissance platforms could be transformed if this method scales effectively. While the energy density of supercapacitors does not match that of lithium polymer batteries, their rapid recharge capability presents a compelling alternative.

In the coming years, at least one commercial micro drone trainer utilizing a hybrid supercapacitor and battery storage system is expected to enter the consumer market. The supply chain for small farad cells is well-established, and the demand for a toy that charges quickly from a USB port is evident.