Modular wing with integrated elevon

Model Overview & Print Notes

Modular wing segment based on the **Clark Y** airfoil, specifically designed for fabrication using FDM 3D printing in **spiral mode (vase mode)** with a **0.2 mm** nozzle. The geometry was developed with the manufacturing process itself in mind, aiming for a continuous deposition path that reduces interruptions during printing, minimizes geometric variations, and results in a lightweight structure with a high stiffness-to-mass ratio. Each segment incorporates, in a monolithic (*print-in-place*) manner, an **elevon integrated via a *living hinge* mechanism**, eliminating additional components and maintaining a single-piece construction. The design includes: - Clark Y aerodynamic profile. - Two independent elastic clamping mechanisms for **6 mm** cylindrical shafts. - Monolithic, integrated elevon (*print-in-place*). - Removable anti-warping tabs to stabilize the leading edge and trailing edge during printing. The segments are designed to be assembled on a single pair of parallel longitudinal shafts, allowing wings of different lengths to be constructed without additional mechanisms for joining segments. The geometry incorporates details specifically designed for FDM printing, including regions with controlled wall thicknesses to facilitate continuous extrusion paths and small reinforcement elements generated by the controlled merging of adjacent lines. The aileron actuation mechanism is not integrated and is left to the user’s discretion. --- ## Geometry - Profile: Clark Y - Chord: ~108.6 mm - Segment length: 60 mm - Maximum thickness: ~13.3 mm - Approximate weight (PETG): ~8 g ## 3D Printing Settings The model is specifically designed for FDM 3D printing in **spiral mode (vase mode)** using a **0.2 mm** nozzle. The geometry has been optimized to maintain a continuous and stable extrusion path during printing. We recommend using a simple lamination configuration and avoiding parameters that introduce unnecessary changes to the extrusion path. ### Recommended Parameters - **Print Mode:** Spiral / Vase Mode - **Nozzle:** 0.2 mm - **Layer Height:** 0.1–0.15 mm - **Line Width:** ~0.2–0.22 mm - **Speed:** Low to moderate - **Cooling:** Active ventilation depending on the material used - **Recommended material:** PETG The model was manufactured and tested using PETG. Other materials may produce different results due to their mechanical and printing properties. Compatibility with larger-diameter nozzles has not been verified. The model is not designed specifically for printing with a 0.4 mm nozzle. ### Print orientation Position the model with the **flat side featuring the kidney-shaped support tabs facing the heated bed**. In this orientation, the printer’s Z-axis is aligned with the direction of the structural axes of the wing segment. ### Stability During Printing The geometry has a height of approximately **60 mm**, selected to maintain a favorable balance between height and stability during nozzle movement. Auxiliary tabs are also incorporated at the leading edge and trailing edge. These structures reduce the risk of *warping* caused by stresses accumulated during printing. The tabs are printed as part of the model and must be removed after printing is complete. ### Post-processing Removing the anti-warping tabs is simple: 1. Make a cut at the junction of the tab and the wing segment. 2. Remove the tab. 3. If a better finish is desired, make additional cuts. You can use scissors or another cutting tool. No additional assembly is required. Once the tabs are removed, the spring-loaded retention mechanism for 6 mm shafts is ready for use immediately after printing. ### Considerations Regarding Print Geometry Some structural details use small geometric notches designed to generate two lines of approximately **0.2 mm** that remain adjacent and fuse during deposition. These features depend on proper extrusion calibration and the line width used. It is recommended to verify the flow calibration before printing multiple segments.

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