LD-BLD-002  ·  v2.4.6  ·  published  ·  2026-03-30  ·  CC BY-SA 4.0
docs  /  build  /  libdrone — PRUSA CoreOne+ Production Guide

libdrone — PRUSA CoreOne+ Production Guide

About

Complete 3D printing guide for all libdrone structural parts on the Prusa CoreOne+. Covers print profiles, material rationale, orientation rules, support strategy, post-print processing, and coupon verification prints. Mandatory reading before printing any structural part.

About

This document guides the user through the 3D printing process of libdrone Pro platform

HARDWARE PREP

  • Nozzle : 0.6 mm Hardened Steel (mandatory for PCCF and PETG-CF; recommended for all)
  • Spare : Keep one additional 0.6 mm hardened nozzle — PCCF and PETG-CF are abrasive
  • Sheet : Satin or Textured PEI
  • Glue stick: Mandatory for PCCF; not required for PETG, PETG-CF, or ASA

PROFILE: "ARM SHAFT — PETG" (3-Season Primary, above ~0 C)

MATERIAL RATIONALE

PETG arm shaft is the crash-sacrificial element in V2.4.6. Printed VERTICALLY so print layers are perpendicular to the primary bending load at the hub. This maximises inter-layer adhesion strength in the bending direction. Tougher than PCCF on impact, easy and fast to reprint.

CRITICAL ORIENTATION: Shaft must be printed STANDING VERTICAL (motor head up or down). Do NOT print flat. Vertical orientation = layers perpendicular to bending = maximum strength. Verify orientation in slicer before printing. Wrong orientation = discard and reprint.

FILAMENT PREP

  • Fresh sealed spool: no drying required.
  • Previously opened: dry at 65 C for 4 hours if humid.

PRINT SETTINGS

  • Layer Height : 0.15 mm
  • Perimeters : 8
  • Infill : 30% Grid
  • Solid Layers : 6 Top / 6 Bottom
  • Brim : 5 mm (base of vertical print)
  • Supports : Organic, motor head overhang only

FILAMENT SETTINGS

  • Nozzle Temp : 255 C
  • Bed Temp : 85 C
  • Enclosure : Door closed (~30 C ambient)
  • Cooling : 30-40%
  • Glue Stick : Not required on textured PEI
  • Extrusion Mult: 0.96-0.98

MOTOR HEAD NOTES

  • Disable "Thick Bridges" for counterbore surfaces — flat, dense bridge required.
  • MR30 wire channel: verify slicer does not fill routing recess with support.
  • Dovetail cable grooves: verify groove profile clean — no stringing across groove.
  • Inspect after print; redo if bridge sags or groove is filled.

TAB JUNCTION FACE NOTES

  • 2 x M2 through-holes at tab junction face — verify holes are clean and unobstructed.
  • Test fit M2 screw before assembly.

DROP TEST

  • Drop from ~1 m onto hard floor.
  • Acceptance: flex or surface mark; bounce or rattle.
  • Rejection: crack or delamination — re-dry or adjust temperature.

PROFILE: "ARM TAB — PETG"

MATERIAL RATIONALE

PETG tabs are the mechanical connection between arm shaft and X sandwich body. Printed HORIZONTALLY so layers are perpendicular to the pull-out load direction. This maximises strength against being pulled out of the T-slot under crash loads. Tabs are designed to OUTLAST the shaft — they should survive the crash that breaks the shaft, and remain seated in the sandwich for re-use.

CRITICAL ORIENTATION: Tab must be printed FLAT (T-profile face down on sheet). Do NOT print standing vertical. Horizontal orientation = layers perpendicular to pull-out load = maximum strength. Verify in slicer before printing.

PRINT SETTINGS

  • Layer Height : 0.15 mm
  • Perimeters : 8
  • Infill : 30% Grid
  • Solid Layers : 6 Top / 6 Bottom
  • Brim : 3 mm

FILAMENT SETTINGS

  • Same as arm shaft: 255 C / 85 C, door closed, 30-40% cooling

T-LOCK NOTES

  • T-profile lock geometry must be dimensionally accurate to 0.2 mm.
  • Print Coupon 8 (T-lock fit) before full tab production run.
  • Test T-lock: should slide into PCCF T-slot with light hand pressure; no play when seated.

TAB-TO-SHAFT CONNECTION NOTES

  • 2 x M2 through-holes must align with shaft holes.
  • Print coupon assembly (shaft + 1 tab + 2 M2 screws) before production run.

MASS TARGET: single tab <= 1.5 g. Set of 8 (4 arms) <= 12 g.

PROFILE: "ARM COVER ACTIVE — PETG"

MATERIAL RATIONALE

PETG for the cable-side arm cover. Matches arm material for compatible crash behaviour. Heat-set inserts for M2 screws seat well in PETG.

PRINT SETTINGS

  • Layer Height : 0.15 mm
  • Perimeters : 4
  • Infill : 20% Gyroid
  • Brim : 3 mm

FILAMENT SETTINGS

  • Same as arm shaft: 255 C / 85 C, door closed, 30-40% cooling

NOTES

  • Dovetail profile on inner face — verify slide-fit with printed arm before assembly.
  • Heat-set insert bores for M2 screws: verify diameter matches inserts.

MASS TARGET: single Active Cover <= 4 g.

PROFILE: "ARM COVER PASSIVE — PETG-CF"

MATERIAL RATIONALE

PETG-CF for the structural motor-side cover. CF reinforcement increases stiffness and provides the o-ring boss precision needed for floating mount integrity.

SAFETY: FFP3 respirator mandatory during printing AND post-processing. CF dust is a respiratory hazard. Ensure adequate ventilation.

FILAMENT PREP

  • Dry at 70 C for 4-6 hours before use regardless of seal status.
  • PETG-CF absorbs moisture quickly — print from dry state only.

PRINT SETTINGS

  • Layer Height : 0.15 mm
  • Perimeters : 6
  • Infill : 15% Gyroid
  • Solid Layers : 5 Top / 5 Bottom
  • Brim : 3 mm
  • Supports : None if geometry allows

FILAMENT SETTINGS

  • Nozzle Temp : 270-280 C (start at 275 C)
  • Bed Temp : 85 C
  • Enclosure : Door closed
  • Cooling : 20-30%
  • Glue Stick : Not required on textured PEI
  • Extrusion Mult: 0.96-0.98

CRITICAL NOTES

  • O-ring boss geometry (8.0 mm OD, 0.5 mm height): verify dimensional accuracy with calipers before assembly. Boss must seat on o-ring only — never arm surface.
  • Nyloc nut pockets: verify hex pocket depth and width with actual nut before assembly.

MASS TARGET: single Passive Cover <= 5 g.

PROFILE: "X BODY — PCCF Black" (3 identical layers)

MATERIAL RATIONALE

PCCF for all three structural X body layers. High stiffness and dimensional stability in compression. Face sheets of sandwich carry bending loads; PETG tabs (arm tabs) carry shear between layers. Classic I-beam principle. T-slot pockets must be dimensionally accurate — tab fit is critical.

FILAMENT PREP

  • Fresh sealed spool: no drying required.
  • Previously opened: dry at 80 C for 4 hours.

PRINT SETTINGS

  • Layer Height : 0.20 mm
  • Perimeters : 6
  • Infill : 10-15% Gyroid
  • Solid Layers : 5 Top / 5 Bottom
  • Orientation : Flat on textured sheet; disable "Thick Bridges"

FILAMENT SETTINGS

  • Nozzle Temp : 280-290 C (start at 285 C)
  • Bed Temp : 110 C
  • Enclosure : Door closed
  • Cooling : 10-15% max
  • Glue Stick : Mandatory — PCCF damages bare PEI on removal
  • Extrusion Mult: 0.96-0.98

T-SLOT NOTES

  • 4 x T-slot pockets — one per arm. Print Coupon 8 before X body production.
  • T-slot must accept arm tab with 0.2 mm clearance per side — slide fit.
  • Verify with actual tab coupon before committing to full X body print.
  • Tab T-lock pocket must be fully clean — no stringing or infill intrusion.

ROD CHANNEL NOTES

  • 4 x Ø2.2 mm rod channels through all layers. Must align perfectly across layers.
  • Verify alignment by threading rods through all 3 PCCF layers (no tabs) before assembly.

TOP PCCF LAYER ONLY (layer 4 — middle top, NOT the PETG top layer): * Stack pattern holes: 4 x Ø3.3 mm for FC/ESC standoffs. * Dowel pin holes: 2 x Ø2.0 mm at standoff positions — verify clean bore. * GPS bracket mount holes: 2 x Ø3.3 mm front centreline. * NOTE V2.4.6: Sensor mast boss pads and heat-set inserts are in the PETG Top Layer (section [2I]), NOT in this PCCF layer. Do not add boss pads here.

ADVANCED

  • Elephant-foot compensation: ~0.2 mm
  • Cool to 60 C before removal
  • Per-layer print time: bottom ~1.8 hrs, middle ~1.8 hrs, top ~2.0 hrs (boss pads add time)

MASS TARGET: single X body PCCF layer <= 9 g. All three layers <= 27 g.

PROFILE: "BUMPERS — ASA Natural"

MATERIAL RATIONALE

ASA bumpers achieve crush protection through geometry — thin walls, hollow interior. Cracks on hard impact (correct failure mode). Reprint cost negligible.

PRINT SETTINGS

  • Layer Height : 0.20 mm
  • Perimeters : 3
  • Infill : 15% Gyroid
  • Wall thickness: target 1.5-2.0 mm finished

FILAMENT SETTINGS

  • Nozzle Temp: 255 C / Bed: 100 C / Cooling: 20-30% / Glue stick / Enclosure closed

DESIGN NOTES

  • Taper outer wall toward tip — concentrates crack at tip, away from motor bell.
  • Interior hollow is the energy absorption zone — do not fill.
  • Stock at least 8 spare bumpers before maiden.

MASS TARGET: set of 4 <= 12 g.

PROFILE: "GPS/CAMERA BRACKET — PETG Natural"

MATERIAL RATIONALE

PETG Natural for the front bracket. Not crash-consumable — positioned at front but protected by bumpers. Needs dimensional accuracy for GPS and camera pockets.

PRINT SETTINGS

  • Layer Height : 0.15 mm
  • Perimeters : 4
  • Infill : 20% Gyroid
  • Brim : 3 mm

FILAMENT SETTINGS

  • Nozzle Temp: 255 C / Bed: 85 C / Cooling: 30-40% / No glue stick / Door closed

NOTES

  • Camera tilt pocket: verify tilt angle accuracy with protractor or CAD measurement.
  • GPS pocket: verify M10Q-5883 sits flush with no gap.
  • MIPI cable channel: verify cable passes freely — no slicer-generated wall across channel.
  • V2.4.6: NO VTX pocket. Bracket carries camera + GPS only. VTX is in Platform electronics zone.
  • Print Coupon 9 (bracket camera/GPS fit) before full bracket print.

MASS TARGET: bracket <= 8 g.

PROFILE: "SENSOR MAST & CRADLE — PETG Natural"

FILAMENT SETTINGS

  • Nozzle Temp: 255 C / Bed: 85 C / Cooling: 30-40%
  • Door closed / No glue stick required on textured PEI

PRINT SETTINGS

  • Layer Height : 0.20 mm
  • Perimeters : 4
  • Infill : 20% Gyroid
  • Orientation : Mast vertical (base down); cradle flat

MAST DESIGN NOTES

  • 20 x 20 mm base, 2 x 3.3 mm through-holes on 20 mm centres.
  • Hollow square tube body, ~70 mm tall, 2 mm wall.
  • Sensor cradle at top: 55.5 x 26 mm pocket, 1 mm retention lips.
  • Print coupon of base footprint first — verify M3 screw fit before full mast.

MASS TARGET: mast + cradle <= 12 g printed.

PROFILE: "X BODY PETG TOP LAYER — V2.4.6" (clean surface — platform features moved to Platform part)

MATERIAL RATIONALE

PETG for the X body top layer. V2.4.6: this layer is SIMPLE. All platform features (battery rails, GX12 chimney, MIPI channel, wire channels, fan slot) are in the separate Platform part — see section [2J]. This layer carries: sandwich bolt holes, stack pattern holes, bracket mount holes, mast boss pads, rod channels only.

COMPLEXITY: Low. Similar complexity to PCCF base layers. No supports required. Print before the Platform and Backplane.

FILAMENT SETTINGS

  • Nozzle Temp : 255 C / Bed: 85 C / Cooling: 30-40%
  • Door closed / No glue stick required on textured PEI

PRINT SETTINGS

  • Layer Height : 0.20 mm
  • Perimeters : 4 (5 in rail zones — set in modifier mesh if possible)
  • Infill : 30% Gyroid (higher than other PETG parts — rails need strength)
  • Solid Layers : 4 Top / 4 Bottom

ORIENTATION: FLAT on build plate, top face up. No unusual overhangs. No supports required.

SUPPORTS: None required. Feature checks after print: □ Rod channels clear and aligned □ Stack holes: 4 × Ø3.3 mm on 30.5 mm pattern □ Bracket mount holes: 2 × Ø3.3 mm at front centreline □ Mast boss pads: 2 × Ø9 mm × 7 mm tall — walls solid □ Sandwich bolt holes: 4 × Ø3.3 mm Install M3 heat-set inserts in mast boss pads after print cools (Section [6]).

HEAT-SET INSERT INSTALLATION (mast boss pads): After feature checks pass, install 2 × M3 heat-set inserts in boss pads. See Section [6] for full procedure. Inserts go in PETG top layer boss pads. NOT in PCCF layers.

MASS TARGET: X Body PETG Top Layer <= 18 g (V2.4.6 — simpler than V2.4.6, no rails or chimney).

PROFILE: "PLATFORM — PETG Natural" (V2.4.6 NEW — most complex part)

MATERIAL RATIONALE

PETG Natural for the Platform. This is the most geometrically complex printed part in V2.4.6. It carries the battery rails, dual GX12-7 chimneys, MIPI channel, wire channels, fan slot, and attachment posts.

COMPLEXITY WARNING

Print Coupon 10 (GX12-7 chimney bore) and Coupon 11 (battery rail slide) before committing to the full production print. Failures waste ~3.5 hrs.

FILAMENT SETTINGS

  • Nozzle Temp : 255 C / Bed: 85 C / Cooling: 30-40%
  • Door closed / No glue stick required on textured PEI

PRINT SETTINGS

  • Layer Height : 0.20 mm
  • Perimeters : 4 (5 in rail zones and post zones — set with modifier mesh if possible)
  • Infill : 30% Gyroid (higher than standard — rails and posts need strength)
  • Solid Layers : 4 Top / 4 Bottom

ORIENTATION — CRITICAL: Print FACE UP (top surface toward sky, rails and posts extruding upward — no support needed). Both GX12 chimneys extrude DOWNWARD — they are supported overhangs printed as internal voids.

SUPPORT STRATEGY

  • Enable supports ONLY inside the two GX12 chimney bores (D-D profile, 11.87mm OD / 10.80mm flat-to-flat, 25mm deep): Connector A: X=−25 mm, Y=−66 mm Connector B: X=+25 mm, Y=−66 mm
  • Use paint-on support blocker on all other surfaces.
  • Wire channels, MIPI channel, strap slots, fan slot: all self-supporting at 0.20 mm layers.
  • Support material: PETG. Rectilinear, 0.2 mm Z distance. Removes cleanly from chimney bores.

POST-PRINT SUPPORT REMOVAL (repeat for BOTH chimneys): 1. Clear support material from chimney bore with a thin pick or wire. Work gently along the walls. DO NOT ream with a round drill bit — the bore is a D-D profile (anti-rotation flats at ±5.40mm from centre); a 12mm round drill destroys the flats and defeats vibration retention. The bore OD is 11.87mm — a 12mm drill cannot even enter cleanly. 2. Dremel flexible shaft + small burr to clear wire exit slot (6 × 4 mm at chimney base). 3. Insert GX12-7 MALE panel mount connector dry — seat with flats aligned, panel nut must thread. 4. If connector binds: light sanding (180 grit on dowel, following D-D profile). Do not oversize. Connector A wire exit slot: LEFT-facing. Connector B wire exit slot: RIGHT-facing.

FEATURE VERIFICATION CHECKLIST

□ MIPI channel: 16 mm wide × 1.5 mm deep, full nose-to-tail length, clear of debris □ Wire channels: LEFT (−20 mm) and RIGHT (+20 mm), 4 mm wide × 1 mm deep □ Battery lead notch: 8 mm wide × 4 mm deep at battery rear zone, chamfered □ Battery rails: LEFT and RIGHT, 53 mm tall, 41 mm inner width — inner faces flat □ Endstop wall: left end of RIGHT rail only — must be solid, no gap □ Lateral strap slots: 20 mm wide in rail top faces, clear through full rail height □ Connector A boss: Ø14 mm × 3 mm proud, X=−25 mm, Y=−66 mm — measure with calipers □ Connector A bore: D-D profile, 11.87mm OD / 10.80mm flat-to-flat, 25mm deep — verify by inserting GX12-7 male body dry (flats aligned, no binding) □ Connector A wire exit slot: 6 mm × 4 mm at chimney base, LEFT face, clear □ Connector B boss: Ø14 mm × 3 mm proud, X=+25 mm, Y=−66 mm — measure with calipers □ Connector B bore: D-D profile, 11.87mm OD / 10.80mm flat-to-flat, 25mm deep — verify by inserting GX12-7 male body dry (flats aligned, no binding) □ Connector B wire exit slot: 6 mm × 4 mm at chimney base, RIGHT face, clear □ Fan slot: 30 × 30 mm at rear, rear-facing, chamfered, wire channel exits LEFT □ Attachment posts: 3 pairs at Y=+39, −39, −148 mm, X=±17 mm — Ø6 mm, 54 mm tall, M3 bore □ Bracket holes: 2 × Ø3.3 mm at nose (+50 mm), 20 mm spacing

BATTERY SLIDE TEST (mandatory before installing in drone): Slide reference battery (78 × 40 × 53 mm) in from RIGHT. Must seat against left endstop cleanly. Must slide out RIGHT freely with no binding. Battery strap (25 mm wide) must pass through lateral strap slots cleanly. If binding: increase #BattRailInnerWidth by 0.2 mm increments.

MASS TARGET: Platform <= 60 g (rails + dual chimneys + posts).

PROFILE: "BACKPLANE — PETG Natural" (V2.4.6 NEW — lattice exoskeleton)

MATERIAL RATIONALE

PETG Natural for the Backplane lattice. Crash exoskeleton and payload interface. ~65% open area makes it light (~5 g) while providing crash protection and a rigid surface for payload module mounting.

FILAMENT SETTINGS

  • Nozzle Temp : 255 C / Bed: 85 C / Cooling: 30-40%
  • Door closed / No glue stick required

PRINT SETTINGS

  • Layer Height : 0.20 mm
  • Perimeters : 3 (thin beams — 3 perimeters fills the 3 mm beam width)
  • Infill : 99% (solid beams — no infill voids in 3 mm beams)
  • Solid Layers : 3 Top / 3 Bottom

ORIENTATION: FLAT on build plate. 1.5 mm thick part. No supports. The part is essentially a flat lattice sheet — prints fast and cleanly.

FEATURE VERIFICATION CHECKLIST

□ Lattice beams: 3 mm wide, clean geometry, no stringing across open areas □ Battery zone right edge (Y=+39 to −39 mm): fully open — no beam on right edge □ Fan exhaust zone (Y=−138 to −148 mm): fully open — no lattice material □ Connector A boss ring: Ø18 mm OD at Y=−66 mm, X=−25 mm — confirm position with calipers □ Connector B boss ring: Ø18 mm OD at Y=−66 mm, X=+25 mm — confirm position with calipers □ Attachment holes: 3 pairs at Y=+39, −39, −148 mm, X=±17 mm — Ø3.3 mm, clear □ Overall dimensions: 187 × 40 mm — measure with calipers

TEST FIT (before final assembly): Place Backplane on Platform posts. M3 screws should thread into post bores cleanly. Confirm battery zone right edge is fully unobstructed — battery slides out under lattice. Confirm fan exhaust zone is unobstructed.

MASS TARGET: Backplane <= 7 g (target ~5 g — weigh before installing).

MANDATORY COUPONS

COUPON 1 — Rod fit (PETG Natural): 2.05/2.10/2.15/2.20 mm bore block. Tune Extrusion Mult 0.96-0.98 until 2.20 mm slides cleanly.

COUPON 2 — Pinch slit (PETG arm shaft): Insert 2.0 mm rod, tighten M3. Zero play, no crush marks.

COUPON 3 — Motor head (PETG — CRITICAL): Full-scale head: 6.5 mm bores + 7.0x1.5 mm counterbores both faces + MR30 channel. Test o-ring flush; sleeve float; M3 clearance; channel clear.

COUPON 4 — ASA bumper: fit to service notch; hand-crush for breakable compliance.

COUPON 5 — Sensor mast base (PETG Natural): Base footprint only (20x20mm, 2 x 3.3mm holes). Test fit M3 screws into inserts on X body top layer. Confirm flat seating.

COUPON 6 — Arm Cover Passive (PETG-CF): Print o-ring boss section and one nyloc pocket. Verify: boss OD 8.0 mm, height 0.5 mm (calipers). Verify: nyloc pocket accepts M3 nut with no slop and no binding.

COUPON 7 — Dovetail groove fit (PETG shaft + PETG Active Cover): Print 50 mm shaft section with full groove profile. Print matching Active Cover section. Verify: cover slides onto arm with no binding; no gap > 0.3 mm.

COUPON 8 — T-lock fit (PETG tab + PCCF X body layer — CRITICAL V2.4.6): Print one arm tab (full size). Print 50 mm section of X body layer with one T-slot pocket. Test: tab slides into T-slot with light hand pressure. Test: seated tab has zero lateral play. T-lock fully engaged. Adjust clearance (#TabLockWidth tolerance) if binding or play. DO NOT print full X body layers until Coupon 8 passes.

COUPON 9 — GPS/Camera bracket fit: Print bracket camera pocket and GPS pocket only (top 30 mm of bracket). Test: camera frame seats correctly in tilt pocket. Test: M10Q-5883 seats flush in GPS pocket. Test: MIPI cable passes through internal channel without pinching.

COUPON 10 — GX12-7 chimney bore (V2.4.6 — CRITICAL before full Platform print): CONNECTOR POLARITY: MALE panel mount in drone (pins up), FEMALE cable mount on payload. Print ONE coupon block — it validates both chimneys (identical bore geometry). Print a 30 × 30 mm block, 30 mm tall, with: - Ø14mm boss, 3mm proud on top - D-D bore profile: 11.87mm full diameter, 10.80mm flat-to-flat (NOT a simple round hole — must have anti-rotation flats) - Ø18mm OD chimney, 25mm deep, downward from block bottom - 6 × 4mm wire exit slot at chimney base Print with same settings and supports as full Platform print (section [2J]). Test 1: GX12-7 MALE panel mount body slides into D-D bore — fits without binding. Test 2: Connector body does NOT rotate in bore (flats grip correctly). Test 3: Panel nut threads fully without cross-threading. Test 4: Wire exit slot clear — 6-wire bundle (6 × 28AWG) passes through. Test 5: Support removal clean — no torn walls inside chimney bore. ADJUST: If connector binds on flats, increase flat-to-flat by 0.1mm increments. If connector rotates, decrease flat-to-flat by 0.1mm increments. DO NOT print full Platform until this coupon passes all five tests. NOTE: Connector A wire exit faces LEFT, Connector B faces RIGHT — same bore geometry, only exit slot orientation differs. One coupon validates both. RETENTION: After Platform print, install connector with double nut + Loctite 243 blue.

COUPON 11 — Battery rail slide test (V2.4.6 — CRITICAL before full Platform print): Print a 100mm section of both rails (left and right) with base plate 10mm thick. Battery dims: 78 × 40 × 53mm. Rail inner width 41mm. Rail height 53mm. Include: endstop wall on right rail left end, lateral strap slot in both rail tops. Test 1: Slide reference battery (78 × 40 × 53mm) in from right — must seat against endstop cleanly with no binding. Test 2: Slide battery out from right — must release with light hand pressure, no snagging. Test 3: Battery strap (25mm wide) passes through lateral strap slots cleanly. ADJUST: If binding, increase #BattRailInnerWidth by 0.2mm increments in Variables. DO NOT print full Platform until this coupon passes all three tests.

PRODUCTION RUN ORDER

  1. PETG Natural coupons (1-3) — ~1 hour.
  2. PETG/PCCF T-lock coupon (Coupon 8) — ~1 hour. MUST PASS before step 4.
  3. PCCF X Body layers x3 — ~5.5 hrs total. NOTE V2.4.6: Heat-set inserts go in PETG Top Layer (step 4), NOT in PCCF layers.
  4. PETG Top Layer — X Body (full print, section [2I]) — ~1.5 hrs (V2.4.6: simple layer). After print: install 2 × M3 heat-set inserts in mast boss pads (Section [6]).
  5. Platform coupons (V2.4.6 — before full Platform print): 5a. Coupon 10 (GX12 chimney bore) — ~45 min. MUST PASS before step 5c. 5b. Coupon 11 (battery rail slide) — ~1 hour. MUST PASS before step 5c. 5c. Platform (full print, section [2J]) — ~3.5 hrs. After print: support removal from GX12 chimney bore. Verify connector fit + battery slide.
  6. Backplane lattice (section [2K]) — ~1.0 hr. No supports.
  7. PETG Arm Tabs x8 (2 per arm) — ~2 hrs total. Horizontal orientation. Dry-fit all tabs into T-slots. Verify T-lock engagement before proceeding.
  8. PETG Arm Shafts x4 (primary set) — ~3.5 hrs each, vertical orientation.
  9. PETG Arm Shafts x2 (spares) — same settings.
  10. PETG-CF Arm Cover Passive x4 — coupon first (Coupon 6), then production. FFP3 respirator mandatory.
  11. PETG Arm Cover Active x4 — coupon with arm section first (Coupon 7).
  12. ASA Bumpers x8 + 4 spares (~1.5 hrs total).
  13. GPS/Camera Bracket x1 — coupon first (Coupon 9), then full bracket.
  14. Sensor mast coupon (PETG Natural) — 20 min. Test fit. Then full mast.
  15. Sensor mast + cradle (PETG Natural) — ~1.5 hrs.
  16. Payload mast variants (PETG Natural) — as needed per payload build.

DURATION: ~50 print hours over 6-7 days (V2.4.6 — +8 hrs vs V2.4.6 for Platform + Backplane).

POST-PRODUCTION & SURFACE SEALING

1) DROP TEST (PETG shafts): flex/bounce — no cracking.

2) HEAT SEAL: sweep structural parts at 250 C for ~15 s. FFP3 mask mandatory — PCCF and PETG-CF dust is hazardous. Seal: arm shafts, arm tabs, X body PCCF layers. Do NOT heat-seal: covers, bracket, sensor mast/cradle, or bumpers. Perform BEFORE any assembly.

3) EPOXY WIPE COAT: single thin coat on shafts, tabs, and X body PCCF layers only. Not required for covers, bracket, mast/cradle, or bumpers. Avoid epoxy in T-slot tab contact zones — maintain slide fit. Avoid epoxy in rod channels and heat-set insert bores. Full cure before assembly. IPA wipe after.

4) CONFORMAL COATING: electronics only — see Software doc.

5) SANDWICH ASSEMBLY: Insert tabs into T-slots. Layer PCCF layers. Thread rods (aligns all layers). Install M3 sandwich bolts. Torque 0.3 N m.

6) SHAFT-TO-TAB CONNECTION: M2 x6 stainless, 2 per tab, 4 per arm. Torque finger-tight + 1/4 turn.

7) PINCH CHECK: insert rods, tighten M3 pinch bolts to zero play. Tap rod; target: 2.2-2.6 kHz. Above 2.6 kHz before zero play: STOP.

8) MOTOR MOUNT ASSEMBLY: per Master Specification. Torque motor screws 0.4-0.5 N m. Zero lateral motor play. Passive Cover: confirm air gap visible — cover must not touch arm surface.

9) MR30 CONNECTOR INSTALLATION: solder female MR30 to motor wires. Route pigtail through arm head wire channel under Active Cover. Label M1-M4. Tug-test: should not pull free under 5N.

10) ARM COVER INSTALLATION: Active Cover: route cable in groove, slide cover onto dovetail, install 2x M2 screws. Passive Cover: lower onto o-ring bosses, install M3 motor screws, nyloc nuts in pockets.

HEAT-SET INSERT INSTALLATION — X BODY PETG TOP LAYER SENSOR MAST BOSSES

Done once per X body PETG top layer, immediately after print has cooled. NOTE V2.4.6: inserts go in the PETG top layer boss pads ONLY. Not in PCCF layers. Not in Platform.

TOOLS: Soldering iron 200-210 C / flat hard surface / M3 x4mm brass inserts (4.6mm OD)

PROCEDURE

  1. Place X body top layer flat, boss pads facing up.
  2. Set iron to 200-210 C. Stabilise 2 min.
  3. Place insert on boss bore — sits centred in chamfered entry.
  4. Press iron onto insert top. Gentle downward pressure. 5-8 seconds.
  5. Stop when insert top face is flush with boss surface. Remove iron immediately.
  6. Cool undisturbed 60 seconds.
  7. Quality check: thread M3 screw by hand — engages cleanly, backs out smoothly.
  8. Repeat for second insert.

IMPORTANT: Install inserts BEFORE epoxy wipe. Epoxy in threads will ruin them.

Sequence: print → cool → insert installation → epoxy wipe (avoid insert bores).

MASS TARGETS BY PRINTED PART

Part Material Target Mass
X Body PCCF layer x1 PCCF <= 9 g
X Body PCCF layers x3 PCCF <= 27 g
Arm Shaft x1 (PETG) PETG <= 15 g
Arm Shafts x4 (primary set) PETG <= 60 g
Arm Tab x1 (PETG) PETG <= 1.5 g
Arm Tabs x8 (full build) PETG <= 12 g
Arm Cover Active x1 PETG <= 4 g
Arm Cover Passive x1 PETG-CF <= 5 g
Cover sets x4 (Active+Passive) PETG/CF <= 36 g
ASA Bumpers x4 ASA Natural <= 12 g
GPS/Camera Bracket x1 PETG Natural <= 8 g
Sensor mast + cradle PETG Natural <= 12 g
M3 inserts x2 (X body) Brass ~2 g
O-rings + sleeves (per build) Silicone <= 3 g
Frame structural total <= 115 g

"AIRCRAFT IS BORN IN THE SLICER, THEN WEIGHT-CHECKED ON THE SCALE."

Revision History

Version Date Author Summary
3.4.3 2026-03-27 JS Chimney bore updated to D-D profile. Drill reaming instruction replaced with pick/wire clearing. Checklist updated to male dry-fit test. Backplane width corrected to 50mm.
3.4.0 2026-02 JS Platform section added (2J). Backplane section added (2K). Battery dimensions corrected.
3.3.0 2025-12 JS Three-layer architecture. X body top layer simplified.