01 / Plan & prototype
Plan & prototype
Developed original geometry through hand sketches and a cardboard mock-up.
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Ultralight foam-board
01 / Aircraft design & electromechanical integration
Ultralight foam-board
RC aircraft
Aerodynamics · Fabrication · Electronics
Designed and fabricated a fully functional remote-controlled aircraft from scratch, then integrated the propulsion, radio, and control systems into an approximately 400 g airframe.
Watch first flightSuccessful first try · More than six minutes airborne
Prototype specificationsLightweight structure,
Lightweight structure,
integrated flight systems
Every cut, joint, and component position affected structural strength, center of gravity, and flight performance.
- Wingspan
- 150cm
- Flying mass
- ~400g
- Build time
- 36hours
- Successful flight
- >6min
The brief
Build a flyable aircraft from scratch
Built at home in approximately 36 hours, the project challenged me to create the airframe geometry myself instead of assembling a supplied aircraft design.
I moved from hand sketches and a cardboard mock-up to a 5 mm foam-board airframe, then integrated a motor, electronic speed controller, battery, receiver, and four servos.
The challenge
Achieve sufficient strength, predictable control, and a stable center of gravity while keeping the finished aircraft light enough to fly.
The approach
Prototype the geometry, fabricate the airframe carefully, use components as functional mass, and verify balance and control response before flight.
Development process
Design, build & flight-test process
Original photographs document the project from early geometry through final control checks.
02 / Fabricate
Fabricate
Cut, scored, folded, and assembled the wing, fuselage, and tail surfaces.
03 / Balance & integrate
Balance & integrate
Installed the propulsion and radio systems, then positioned components to establish the center of gravity.
04 / Flight test
Flight test
On its first flight attempt, the aircraft remained airborne for more than six minutes.
Engineering the details
Strength, balance & weight
Secure wing attachment
I rejected an initial magnet concept and made custom foam interfaces that increased bonding area and created a stronger fixed wing joint.
Balance with useful mass
The 3S 1200 mAh battery provided necessary forward mass. I shifted the battery and electronics until the aircraft balanced level or slightly nose-down.
Reinforce selectively
A wood plate carried the motor loads, while hot glue and fiberglass tape were applied sparingly elsewhere to preserve a low flying mass.
Build notes
Materials & specifications
| Wingspan | 150 cm |
|---|---|
| Length | 112.5 cm |
| Wing chord | 20 cm |
| Airframe mass | 250 g excluding battery |
| Estimated flying mass | Approximately 400 g |
| Build time / cost | 36 hours / approximately US$80 |
Airframe materials
5 mm foam board, a wood motor mount, fiberglass tape, hot glue, general-purpose adhesive, and metal control linkages.
Electronics
BR2208 1400KV motor, 7-inch propeller, 12 A electronic speed controller, 3S 1200 mAh battery, Lemon RX six-channel stabilizing receiver, Spektrum DX6 transmitter, three SG90 9 g servos, and one 5 g rudder servo.
Mass, cost, and flight time reflect the prototype shown.
Outcome & lessons learned
A successful
first flight
The aircraft flew successfully on its first attempt and remained airborne for more than six minutes before the battery required recharging.
Designing the airframe from scratch made geometry, structure, balance, propulsion, radio control, and servo actuation one connected system. The result showed the value of careful planning, precise fabrication, and disciplined weight management.
Next project
Adjustable scissor-lift lamp
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