https://youtu.be/ZFsPNsgbl4M?si=zIL2vU36YqccKjv3

The Story

I’ve had on my bucket list to develop a massive RC airplane for a long time. I like how large RC planes feel in the sky and wanted to see how large I could make it. However, using that much foam would be wasteful, and balsa too expensive. So, I decided to make the plane fully out of cardboard.

Design and Analysis

Design

• Modeled using Fusion 360's sheet metal tool.
• Laser-cut on standard 1/8" corrugated cardboard.
• Cardboard crumple zone protects the battery in case of a crash.
• Rigid fuselage structure built with alternating corrugation weaves and a thin outside cardboard skin.
• Designed wing bending to follow the contours of corrugation, improving bend geometry over foamboard.
• Modular wing design retained with wood pins for easy removal during transport.

Control

• Six channels, featuring differential thrust and flaperons.

https://youtu.be/PBnucU3jc4s?si=vH5YZXtnLuF0DPQu