My 3D printed/foamboard hybrid RC 3D plane with 80cm wingspan.

This is designed to be a 3D aerobatic plane. It flies well, and can perform aerobatics and 3D manoeuvres - https://youtu.be/s93wCArZ8a8

The plane is a combination of 3D printed parts, flite test style 5mm foamboard, and lollipop sticks.

The 3D printed parts are included as 3mf files (including a stl and step file of the whole plane, to help with construction).

The plans for the foamboard cutouts are included as a pdf - planeprint.pdf. It is designed for A4 paper, just print without applying any scaling and it should be accurate. you can then use this to cut out your foamboard. Some of the lines represent scores to be folded, rather than full thickness cuts. These scores include those for the:
elevator
ailerons
rudder
leading edge
tab at edge of nose and tail piece

Also, the lines between the A4 sheets are marked to help alignment. Don't cut these!

All others are full thickness cuts. The plans include servo mounting holes for the aileron servos, and control horn mounting locations. planeprintplan.pdf is a view of the entire 3x3 A4 sheets - for orientation.

The 3D printed parts will all need to be printed and assembled as shown in the 3mf file and photos. The fuselage is the correct orientation for printing - it has a flat bottom to help with this. It should be printed with supports. Orienting the other parts is straightforward. I used 0.2mm layer height.

I used normal PLA, solid (the walls of these pieces are 1.2mm thick, so it isnt too heavy).

The hatch slides into place - slide the front piece first, then the rear piece.

The plane is designed for use with 9g servos. These mount inside the fuselage, and in the wings. There are routing holes for the pushrods in the 3D printed tailpiece.

I used a T-Motor AT2312 1150KV Fixed Wing Motor, 30A ESC and 10x4 prop. 3S 850mAH battery. My plane in total weighs 570g, the motor has a thrust of up to 1200g.

There is no instructional video for curling the foamboard - you will need to remove the paper from the inside of the sections to be bent, and to curl the foamboard by pressing it against a table edge. All the techniques are the same as those used in flite test foamboard planes.

I taped the foamboard once I had formed the cylinders for the nose and tail.

The lollipop sticks measured 8.5x65.0x2.0mm.

I used gorilla clear glue to glue all pieces in place. I also used this on the hinges, and all exposed foamboard edges, to prevent the paper from peeling.

CG is roughly 47mm back from the leading edge.

Enjoy!!!