3D-Printed Stallion Drone Offers DIY Fixed-Wing Flight with Optional VTOL Capability

A refreshed version of the fully 3D-printable Stallion fixed-wing drone has been unveiled, featuring twin motors, V-tail configuration and optional VTOL capabilities for versatile flight operations. The aircraft boasts a wingspan of just over 130cm (51 inches) and measures nearly one meter (39 inches) in length, designed primarily for lightweight PLA filament with additional components printed in more rigid materials like PETG.

Technical Specifications and Printing Requirements

The Stallion can be printed on 3D printers with a minimum bed size of 220x220mm (8.7×8.7 inches) and 200mm (7.9 inches) print height. The design files accommodate different printer capabilities, offering split fuselage components for smaller printers and single-piece versions for larger machines. The demonstration build utilized the Elegoo Neptune 4 Max printer with its 420x420x480mm (16.5×16.5×18.9 inches) print volume, capable of temperatures up to 300°C and print speeds reaching 500mm/s, allowing for carbon fiber-reinforced filaments.

Assembly Process

The assembly begins with gluing the fuselage components together using 2mm filament pieces as alignment guides and thick CA glue for bonding. Various reinforcement elements printed from PLA or other rigid materials strengthen critical connections like the wing-fuselage junction. The tail assembly integrates servos directly, with cables routed through the 16mm carbon tube tail boom.

Wing Construction and Attachment System

The wings utilize a 6mm carbon tube as the main spar, with all segments glued together and reinforced at the wing root. A clever attachment mechanism employing torsion springs from hair clips creates a secure snap-fit lock system that allows wings to be attached and detached from the fuselage with a single motion. Similarly, the tail connects to the fuselage via a threaded mounting element that ensures proper alignment.

Control Surfaces and Electronics

Control surfaces use thin CA polyester hinges, with M2 threaded rods and metal snap links connecting servos to control horns. The aircraft features T-Motor F60 1750KV motors mounted in the wings. Optional 2812 LEDs can be installed on the wing tips and covered with transparent PLA prints. The nose section can accommodate different camera options, including a standard 19x19mm FPV camera with internal VTX or a Caddx GM3 gimbal.

Electronics Configuration

For electronics, the build features a SpeedyBee F405 Wing flight controller, Matek M10Q GPS, and an ELRS RC link. The creator provides wiring diagrams showing recommended equipment layout, connections, and servo/motor channel assignments, along with ArduPilot parameter files for the SpeedyBee F405 Wing controller as a starting point for configuration.

VTOL Configuration Option

The Stallion can be built in a VTOL version with a tricopter configuration using tilt motors at the front. This variant has been demonstrated in flight videos available on the creator’s channel, with a dedicated build video for the VTOL conversion planned for future release.

Documentation and Resources

Complete design files, including STEP format for frequently modified components, are available on the creator’s website. The documentation package includes printing guidelines, a full bill of materials, electronics requirements, and an illustrated build guide. Additional resources like parameter files for ArduPilot configuration with documented breakdowns are available through the creator’s Discord server.

Required Accessories

Recommended Electronics