Fab-in-a-Box Balsa Glider: Deep Dive

Setup and Preparation:

Prepare by designing and cutting several diverse glider examples that demonstrate a range of design strategies, such as long wingspans, swept wings, or unconventional tail shapes. One of these should be cutting live as learners arrive to inspire creativity and signal the open-ended nature of the task. Blank xDesign templates should be ready for learners to begin from scratch.

Welcome:

Welcome the class and explain that learners will be using the Engineering Design Process to guide their work, starting with planning and modeling, then building, testing, and improving their designs from scratch. Emphasize that this process is iterative and experimental, and that every test flight is a chance to learn and improve.

Context:

Planes’ designs must balance all of these forces. The shapes, sizes, and materials used for the wings, body, nose, and tail can all drastically affect the way a plane flies. How can you engineer a plane to take advantage of these forces?

5. Aerodynamic: of or having a shape which reduces the drag from air moving past.

6. Fuselage: the body of a plane

7. Horizontal Stabilizer: the tail of a plane

8. Engineering Design Process:

In the Real World: Engineers don’t create perfect designs on the first try. They test, redesign, and retest their ideas again and again, making small changes each time based on their observations. This is called iterative prototyping, and it’s a key part of the engineering design process. Instead of thinking of mistakes as “failures,” think of them as rough drafts of a finished product. Each one is a step closer to success!

Key terms:

Key Science Concept: Aerodynamic Forces

Four main forces keep planes in the air: thrust, lift, gravity, and drag.

1. Thrust: the force propelling a plane forward. Thrust is most often generated by fuel combustion (or your throw!). 

2. Lift: the force acting upward on a plane’s wings to keep it aloft. Lift is generated as a plane moves forward and air moves more quickly across the top of its wings than beneath them. Generally, the larger the wings, the greater the lift.

3. Gravity: the force pulling a plane’s mass down toward the ground. Lighter materials can help a plane stay airborne longer.


4. Drag: the frictional force a plane experiences from air flowing past it. Drag is the opposite of thrust, and slows a plane down. It is largely influenced by its tail design.

Which of these forces act against each other? 

Which forces are present when a plane is sitting stationary on the ground? 

What about taxiing in (rolling along) the runway?

Consider:

Basic shapes to build the body, wings, and tail.

The mirror tool to make the design symmetrical.

Path editing tools to adjust curves and fine-tune the shape.

The 3D printed nose cone for this lesson will be fully designed by the learners.

Ideate:

Optimize the gliders performance by designing the shape of its wings, tail, body, and custom nose weight.

For xDesign Steps Click Here

xDesign steps can also be found:

In xDesign under Content

xDesign:

Open xDesign and navigate to the Content section.

Create a new blank file.

Save the file using the naming convention provided by your instructor: JoeGliderV1

Use this blank template to begin designing your custom glider.

Apply the concepts and techniques learned during the Exploration level of this lesson to guide your design process.

Laser Cut Fuselage (body)

Connect laser cutter:

Turn the laser cutter on and connect it to your computer via USB

Open xTool’s XCS software

Select “connect device” in the upper righthand corner of XCS

Choose your laser cutter from the pop-up menu

Import design file:

Click the file folder icon in the upper lefthand corner. From the dropdown menu, select “import image.” Choose your file.

Select the circular handle to rotate your design as needed to fit onto your stock.

Note: Do not resize within XCS! Remember: your design is parametric, and the slots are perfectly calibrated for the width of your stock material. If you resize outside of your CAD environment, the slots will also change.

Configure cut settings:

Select “user-defined material” from the dropdown materials list.

Combine all elements (lines) you want to cut on a single layer.

To add or switch layers, click “move to.”

Select “cut” under the “processing type” menu.

Check settings

For 1/16” balsa wood, we suggest the following (power/speed/pass):

Score: 40/150/1

Engrave (raster): 30/200/1

Cut: 100/15/1

Note: the machine will automatically score and engrave before it cuts, and cut inside elements before outside elements.

Prepare laser cutter:

Open the laser cutter lid and place stock (balsa) onto the honeycomb.

Manually drag the laser head over the center of the stock.

Close the lid.

Click “auto focus” and wait for the machine to focus.

Open the lid. Manually drag the laser head to the top left corner of the desired cutting area.

To check framing, click “framing” in XCS and then press the button on the machine. The laser head will frame the area to be cut. If it does not fit on the stock or overlaps a previous cut, adjust the starting position as needed.

Run the job:

Click “process” in XCS, followed by the button on the machine.

Remove pieces:

Check to make sure all pieces are cut through, and

rerun (adjusting settings as necessary) if not.

Remove workpieces and scrap from the machine.

Close the lid.

Vinyl Cut (wings and tail)

Prepare the machine: 

To turn the machine on, long-press the power button on its right side for 2-3 seconds.

Open the machine’s hood.

On the tool carriage, pull the locking mechanism completely out.

Place the autoblade into the tool slot, and make sure it is fully inserted.

Push the locking mechanism back into place.

Prepare the cardstock:

Use a light hold cutting mat (or one where most of its “sticky” has worn off.”

Position your cardstock on the paper.

Load prepared cutting mat into the machine.

Configure cut settings:

Turn off half cut.

Run job:

Click “send.”

Remove your pieces:

Don’t peel the paper off the cutting mat! Instead, turn the whole thing upside down and peel the cutting mat off the paper instead.

Assemble:

Insert wings through the slot in the plane’s fuselage (body). Make sure they’re centered; the notch will help keep them in place.

Slot your horizontal stabilizer (tail) into place.

Optional: add a paperclip nose weight! (Tape and pennies also work).

Note: If time allows, have learners create vinyl sticker decals to decorate their gliders.

3D Printing (nose cone)

Prepare & Slice Files:

Open your slicing software: Bambu Studio

Import your design into the slicer:

This is easy: you can just drag and drop!

Select the type of printer you’re using (P1S).

Select the bed type.

Select the filament type being used (PLA).

Select the slicing settings.

Click “slice.” This will create a .3mf file and take you to a preview window that shows you what your finished design looks. Your dice is now ready to print!

Launch Print:

You have two options to launch your print:

1) send it wirelessly

2) us an SD card.

The printer will likely run an automatic leveling check before printing. This usually takes a few minutes.

Test and Evaluate

Stand in the same spot and attempt to apply the same force for each launch.

Note: This is best done in a hallway or gym. Using a line of tape on the ground will help students with throwing from the same spot)

Measure and record the glider’s distance traveled after each

flight.

Optional math tie-in: launch at least three times and calculate the average distance traveled.

Redesign and Try Again

Adjust your design files and try again.

This works best if you adjust only one part at a time!

Discussion Questions:

What inspired your initial design idea?

How did your design evolve through testing and iteration?

What data helped you make decisions about your next version?

How did you balance creativity with functionality in your design?

What would you recommend to someone starting this challenge for the first time?

Optional: have students present their projects in a “mock round table” discussion. This can benefit students in their understanding of peers’ design process and how to lift one another up.

Optional Tie-ins:

Historical Figures in Aviation:

Wright Brothers: Discuss the pioneering work of Orville and Wilbur Wright in developing the first successful powered airplane. Highlight their use of engineering principles and experimentation, which can inspire students as they design and test their own gliders.

Amelia Earhart: Explore the achievements of Amelia Earhart, the first woman to fly solo across the Atlantic Ocean. Her story can motivate students to pursue their own aviation-related projects and careers, emphasizing the importance of perseverance and innovation.

Howard Hughes: Examine the contributions of Howard Hughes to aviation and aerospace engineering. His work on advanced aircraft designs and record-breaking flights can provide context for the engineering challenges and opportunities in aviation.

Charles A. Lindbergh: Discuss Charles Lindbergh’s historic solo nonstop flight across the Atlantic Ocean. His achievements can serve as a case study in the importance of aerodynamics, endurance, and the human spirit in aviation.

Career Connections:

Learning to design and fabricate gliders using CAD software, a laser cutter, vinyl cutter, and 3D printer, opens up a variety of exciting career paths:

Aerospace Engineer: Highlight the role of aerospace engineers in designing and testing aircraft, spacecraft, and related systems. Discuss how the skills learned in designing and building balsa gliders can be foundational for a career in aerospace engineering.

Aviation Specialist: Explore the various careers within the aviation industry, including pilots, air traffic controllers, and maintenance technicians. Emphasize how understanding the principles of flight and aerodynamics is crucial for these roles.

By exploring these connections, students can see how the skills they develop in this lesson can be applied to various professional fields, inspiring them to pursue their interests and passions.