Foldable Nano Quadcopter FNQ220 (parametric OpenSCAD)

UPDATE 04-APR-2018:
REPLACED by Version 2 - see Thingiverse object "FNQ220 V2, object #2850976"

UPDATE 23-APR-2016 (see openscad file V.24):
- Bugfix: Boom flight position stoppers adapt to QUAD_W > 50°
- Feature: Stoppers with cylindrical filled frame geometry (StopperFill)

UPDATE 04-MAR-2016 (see openscad file V.23):
- Bugfix: boom slots are symmetric now, even with Quad_W > 45°
- Additional "top cover" added for customizer selection ("cov") e.g. for GPS
- Some parameters fine tuneable

UPDATE 28-FEB-2016 (see openscad file):
V.22 adapted to Customizer:
- Most components selectable via customizer
- Main dimensions and features are widely customizable
- Boom hinge optimized for better motor cable packaging
- Top frame optionally w/o flight controller fixing domes
- Legs with variable extended height for "low hanging" gimbals
- Many more small optimizations due to customizer calculations

UPDATE 25-07-2015 (see openscad file):

V.20 with additional motor type:

- Boom with holder for motor DYS BX1306 (HK #66402) added

(motor with standard fixation concept by 4 screws), very robust!

see openscad file (or fnq220_boom-bx1306_v19.stl)

- Remark: This boom is printed with the propeller side up

(the HK2811 boom must be printed upside down)

- Adapter plate for FC Flip32-mini added (fits onto 31x31 footprint)

- Remaining parts are unchanged (can be used from V.18)

- My "FNQ #2" is coming (black magic PLA) with the DYS motors

--> see gallery photo...

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UPDATE 19-07-2015 (see openscad file):

V.18 with significant improvements over V.15:

- Motor holder strengthened (robust motor fixation even with PLA)

- Legs strengthened (can be printed rotated sideways)

- Lower case strengthened (wider ESC holders)

- Default size increased to 90x70mm

- Plate for FC with 30.5 x 30.5mm footprint (Naze32, CC3D, Flip32)

- Antenna holder for Jeti RSAT (optional)

- LED holder for 2 x Neopixel 5x5mm (optional)

Maiden flight went perfect with this version (using Lipo 2s 800mAh, HK 2811-2000 motors, AfroFlight rev5, Jeti RSAT1).

A small quadrocopter with 220mm motor distance for direct drive motors. All booms are foldable, so it fits in a small bag to carry everywhere... 10g brushless HK 2811-2000 motors plug into the motor holder w/o additional fixing bracket, their cables are protected inside the booms. Between lower and upper frame there is space for 4 x Plush 6A ESCs and a flight controller with 30.5x30.5mm or 45x45mm footprint sits on top.

All components are designed to be printed in PLA w/o additional support structures. The hollow booms are weight optimized and fixed with M3 screws to the frame, so they can be printed even with tiny 3D printers.

The complete quad is designed with parametric main dimensions, so it's easy to be "extended" from 86mm frame length up to 160mm, if additional space for FPV, gimbals etc. is required.

The frame parts have simple design, only with fixation for ESC, battery and FC. Further bling-bling may be added later. Feel free to play with the design!

The design started with the idea to create a parametric motor mount for smaller brushless outrunner motors for my little quadrocopters.

Adding the "fold" feature and a frame all around it was a lot of fun with OpenSCAD, all components are written with parametric dimensions.

Everything prints w/o heat bed and w/o additional support structures in PLA on my DIY deltaprinter.

Break away the inner tube in the motor holder, it is only a support structure to print the improved inner motor flange.

Use a 2mm drill for the small thread holes at the motor flange (in PLA drill slowly by hand), then drill a M2.5 thread there. You also can try to set the M2.5 screws which come with the 2811-2000 motors directly if you drill the holes diameter a little bigger before.

The 4x Plush 6A ESC can be placed inside the lower shell, each one in its own chamber, so no shrink tube is required. Use 1 power cable to connect them all in a daisychain. Its a good idea to place the big input elkos on top of the ESC to get more space there.

Check the motor temperature after test flight. The motors should not become too hot, otherwise the motor might become loose in the PLA boom holder. Some drops of CA glue inside the motor holder (before inserting the motors!) could stiffen the structure in this case.

Have fun printing, building and flying your own!