The 3D printed Fixed Wing Aircraft competition challenges students to design and build a remote controlled aircraft exclusively using additive manufacturing. All components of the aircraft excluding electronics must be 3D printed. Teams are judged in two categories. First in design innovation and then in flight duration with an 8 second powered climb to 35ft, followed by an unpowered glide for as long as possible. Therefore to maximize performance involves careful engineering decisions and testing. 

For this project I took lead on many crucial roles. 

• I learned Solid Works and performed CAD modeling of many aircraft components including airfoils, fuselage, and control surfaces.

• I took the lead on manufacturing and assembly, printing all componets and organizing assembly days, and handeling problems as they arise.

• I took lead on organizing flight testing, creating a testing schedule, pre-flight checklist, scouting locations, as well as performing root cause analysis for each test flights performed. 

• Finally I assumed the role as one of the pilots to perform flight tests and competition flights. 

The final aircraft design is optimized for low speed gliding. With a 72 in wingspan, a wing area of 504in^2, and a 10.2 aspect ratio. Modeled similar to high performance gliders. 

• Key design specs include a NACA 4415 main wing airfoil, chosen for its high lift at low Reynolds number and gentle stall behavior. The horizontal stab is a NACA 0015 airfoil with a 15 in tail moment arm for pitch stability. 

• The aircraft sports a rudder elevator configuration for control surfaces to minimize weight. Which is in turn counter acted with 10 degree dihedral wing tips for roll stability. 

• For materials, the wing and tail surfaces are printed from PLA-Aero which is a lightweight foaming filament. The wing spars and tails are printed from PAHT-CF which is a carbon fiber infused Nylon, which provides superior strength and rigidity. 

• Propulsion comes from a 1400kv brushless DC motor mounted to the front in a puller prop configuration, with the ability to fold flat when the motor is cut to reduce drag. 

• The aircraft comes in at a weight of 1.2kg (2.65lbs), well under the FAA limit of 55lbs. 

The aircraft has a modular design, made up of smaller 3D-printed sections connected via internal rods, glue, and friction fits. The modular design allows for rapid repair, with parts being easily swappable during competition.

Finally some challenges encountered are limitations in print volumn, forcing parts to be smaller. As well as challenges with printing with un-common filaments like PLA-Aero and PAHT-CF that required careful attention and print settings for smooth surface finishes. 

Five test were performed prior to competition seen in the chart to the left. Prior to each test, a pre-flight checklist was performed to verify all systems of the plane to ensure valid test results. During test flights, numerous in-air tests were performed to measure aircraft performance and ensure actual aircraft performance matched expected results. Each test flight provided valuable data, allowing us to further improve the design and boost performance. 

Team Cloud 9 finished in 4th place overall for flight time at the 2026 International 3DPAC competition at Cal State LA.

The biggest takeaway was to prioritize testing early on. Giving ample time to flight test and iterate as much as possible. Our iteration speed along with our modular design and rapid prototyping, enabled use to iterate quickly. If I could do the competition again I was ensure design and print settings were locked in very early on, focusing heavy on testing, rather than reasearch and simulations.