Hi guys, I want to share some designs with you I did over the weekend. I was thinking of how to achieve a similar sealing of the battery compartment like the foil drive.
I ended up with 3 parts that need to be glued together (probably with Sikaflex):
Housing
Cover
Sealing lid (sealing ring needs to be added)
The downsides:
total height ~35 mm vs 25 mm for 1p batteries
more weight
more expensive due to 2 additional parts having to be printed in aluminum (maybe petg would be enough for the cover and lid, though?)
added complexity
What do you think guys, is it worth pursuing this?
Is the sealing of the battery with the pad a problem at all?
@Bzhwindtalker thanks for all this work you are doing here! It helped a lot reducing uncertainty in some key areas of the design.
Looks great. Just printed my take on this too. Also going for a sealed battery compartment in addition to a gasket around battery connectors and dielectric grease. Hoping that three stages of defense will be enough. In my case, I’m just gluing the lid on. Could have printed in place but it’s nice to see the inside during.
Fun experiments today with foaming tpu for gaskets. Seems awesome so far!
Which brand of Foaming TPU have you gone with and what printer are you using i have tried with oring cord but not had much success and creating the gaskets dont want to sika it together as its a pain to clean off later in the need of repair
I’ve experimented with the Siraya TPU air. Really fun to play with the variable durometer aspect. Though mainly went with this one due to the thorough documentation on settings and what happens at various temperatures. And that they had print profiles (which was a helpful start for a weird material like this). I’m using a Snapmaker U1 which honestly has opened up a world of mechanical designs compared to the other printers I’ve had for years. Kinda abandoned the “underboard” build but glad I’m back to it now.
Just did my homework and had a look on its KickStarter campaign, so many interesting features. How would you compare it to other recent printers you know in terms of print quality, speed, (Bambulab P2S for ex, Elegoo, …) ?
I am trying to cut gaskets from Flexoid paper using the knife tool for the Bambu H2S seems promising, just need to get the thickness of the paper dialed in as the .25mm i tried is not compressing enough.
I had good sucess with eva foam (hobby store stuff) both for assist parts and cooling circuit of my 2 stroke boat motor. It handles significant thickness compression.
At work, I use custom cut foamet seals, aluminum 0.4mm + 2 layers of neoprene (nbr) foam. Good stuff.
Got ti screws for the system and foil, had issues with bending and breaking m8 stainless steel bolts
Some pictures of the unit assembled by arnaud in Corsica. Battery with RS50 cells (best available tabless at the moment, 5.15 AH)
He has designed custom blades, I think he has done static thrust tests with it
No need for any cnc in this project. Print at home or order prints.
Base is alu printed (craft cloud or prototi)
Pod is also 3d printed, ppa-cf fdm or pa12 sls.
Battery box is 3d printed (petg) and battery is cast in place with deep pour casting epoxy.
Blades are alu printed. Hub sls pa12 or ppa-cf.
I think the base could be 3d printed at home too, but thermal could be limiting.
