The answer to this question is actually pretty simple—I love the 747! For some reason, I have been fascinated by this aircraft for a long time. It might be its sheer size or design, but nobody can deny that this aircraft is the queen of the sky. In my free time, I decided to start designing this model in SolidWorks. Since I plan to eventually fly this model, I began with the design of the engine nacelles, as they needed to be able to hold some sort of EDF (electric ducted fan). I chose to purchase four 30mm EDF units for this project and based the scale on their size. The entire model is built using 3D printed parts and was printed using the Bambu X1 Carbon.
Since I decided to manufacture this model using only additive manufacturing techniques, I had to ensure that the design was as light as possible. Most of the body is hollow, and the key structures are cleverly designed to maintain rigidity while keeping the model light and printable.
This aircraft admittedly became much larger than I initially expected, and therefore it has quite a large footprint. The airfoil chosen for this model is actually not accurate to the 747-8i, but it is more optimized for the flight regime of this small model. The wing sweep and planform are almost identical to the actual 747-8i.
The wing was designed in sections, along with the nacelles. All the pieces were designed and toleranced for a perfect fit right off the printer.
Since the shear size of this model is too great for my printer to handle, I designed the fuelage sections in multiple hollow pieces.
The 747 has lots of wheels, and I needed to design a set that was easy to print at this scale while also being functional. These wheel and bogie systems were designed to accommodate carbon rods as struts for added strength.
During the course of this project, I had to do a lot of 3D printing, and my choice of machine is the Bambu X1C. The entire project was printed using PLA plastic, and the model weighs around 1300 grams, including a LiPo battery. Given that the aircraft has four EDF units, each producing 200 grams of thrust, the aircraft's thrust-to-weight ratio is around 0.62. Comparing this to a real 747 with a thrust-to-weight ratio of around 0.3, you would think I would be in the clear to fly. However, because of scaling effects, I plan to reprint the project using a lighter material. There are more material options for my printer that have similar material properties but a much lower density.
Since this is a more recent project, I have only been able to conduct brief taxi tests indoors. In this video, you can see the 747 rolling down a hallway with all four EDFs. If you notice a missing piece of the fuselage, it's simply because I didn't have it on during testing for access reasons.
Since I plan on flying the aircraft, it obviously needs control effectors to steer it. In this video, you can see that I've found a way to incorporate micro servos into the wings and horizontal stabilizers to create large and functional control surfaces. It should also be noted, though not featured in the video, that the nose gear is, in fact, steerable.