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3DLabPrint Zivko EDGE 540v3, User Manual

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3DLabPrint Zivko EDGE 540v3 User Manual Download Page 5

page

 5

... print your plane  | www.

3DLabPrint

.com

Included:

1. STL 3d files

Universal STL files designed for use with desktop FDM 3D printers and slicer software such 
as Simplify3D (recommended) CURA or MatterControl (these STLs are not compatible with 
Slic3r or Makerware slicers).

2. Factory files for Simplify3D slicer

with all our settings, these Factory files include all you need. Note: we use PRUSA i3 ORIGINAL 
printers so you may need to adjust the basic printing parameters to match your printer or use 
it  as a starting point for you. Please look at 

Simplify3D

3. Step By Step PDF/VIDEO userguides

Please use this user guide along with the Printing Guide where you can find Tips and Advice 
for airplane printing (Thin Wall Printing).

Summary of Contents for Zivko EDGE 540v3

Page 1: ...page 1 print your plane www 3DLabPrint com Fully 3d printable EDGE 540 V3 73 Martin Sonka replica 25 scale wingspan 1 85m 73in User Guide rev 2019 05 ...

Page 2: ...icks According to the settings and equipment this plane can be recommended to both medi um skilled and even highly experienced 3D aerobatics pilots We hope you enjoy printing building and flying it although this build will truly test your abilities and quality of your printer Welcome to the thin wall printing The first fully printable airplanes with files prepared for your 3Dprinter with flight ch...

Page 3: ...from LE Airfoil 3DLabPrint symetric 02 Weight of printed parts w o wheels 2415 g 72 7 oz Takeoff weight 12s 2650mAh Li Pol 4550 g 160 5 oz Max takeoff weight 5500 g 194 oz Never exceed speed Vne 150 km h 93 mph Design max maneuvering speed Va 75 km h 46 mph Stall speed Vs 28 km h 17mph Performance measurement Max speed VH level flight 140 km h 75 6kn 87 0mph Rate of climb 33 m s 6 500 ft min Fligh...

Page 4: ...mpionship since 2010 1 becoming the World Champion in the 2018 Red Bull Air Race World Championship season Martin Šonka began his aviation career in 1997 In this year he flew a glider for the first time and started his studies at University of Defence in Brno as a pilot In 1999 he gained his Private Pilot Licence Between 2001 and 2005 he attended Jan Perner Transport Faculty at University of Pardu...

Page 5: ...e slicers 2 Factory files for Simplify3D slicer with all our settings these Factory files include all you need Note we use PRUSA i3 ORIGINAL printers so you may need to adjust the basic printing parameters to match your printer or use it as a starting point for you Please look at Simplify3D 3 Step By Step PDF VIDEO userguides Please use this user guide along with the Printing Guide where you can f...

Page 6: ...gonna work with your printer 5 Prepared settings for CURA and MatterControl slicers If you can t use Simplify3D for any reason we provide our basic configuration files for free slicers CURA and MatterControl Use these as a start point and amend as needed 6 Scale markings and masking patern in PDF Print this PDF on self adhesive foil cut it and put it on the model according to your preferences Mart...

Page 7: ...page 7 print your plane www 3DLabPrint com Lenght 1835 mm 72 2 inch Wing area 62 dm2 6 7 sq ft CoG is 104mm 4 09 in from LE Centre of Gravity ...

Page 8: ...page 8 print your plane www 3DLabPrint com Wing span 1850mm 73 inch ...

Page 9: ...part 1 Create account download You ll get the download link for all zipped files to your email or log in to your account and download directly from our website If you don t receive the link right on checkout please contact us on support 3dlabprint com mentioning the order number WC XXXXX on PayPal receipt 2 Gcodes preparing option A Gcodes If your printer is i3 compatible you can directly use the ...

Page 10: ... the use of our settings If you still encounter any dificulties please proceed to the next option option C Simplify3D manual setting watch and learn Use our VIDEOGUIDE and how to to find explanation of proper settings This is great option to learn a lot about Simplify3D and become a 3D expert Of course you spend a lot of time and the youtube pause button will become your friend For simplification ...

Page 11: ...he best extrusion multiplier and temperature for good weight and best possible layer bonding Look at parts weight list for proper multiplier settings Please check the Cura setup guide in the Help section As a starting point you can use our predefined CURA profile Always adapt the settings for your printer change build volume filament diameter etc according to your printer Please be aware some part...

Page 12: ...ot suitable for this Scaling the model will lead to unusable result Note ninja flex or simmilar fillaments can stick very hard to PEI based surfaces be careful You will need PLA filament good quality we need good layer bonding Strong hair spray or your favorite adhesive bed surface disregard with PEI or similar bed surface Mk2 3 Razor blade AND please look at VideoGuides video printing guide 3 EDG...

Page 13: ...warping ends Any standard quality PLA is suitable to print our planes but the result depends on combina tion of PLA vs Extruder vs HotEnd Some colors and brands of filament has lower layer adhesion please do experiment with it There are a lot of 3dprinters on the market most of them are OK for printing our aircraft specific thin wall printing with sufficient volume heated bed 0 4 mm nozzle Please ...

Page 14: ...vator for CA Glue or similar but gas presurized aerosol is better Carbon Fiber Tube hollow 14x750mm or any 750x14 Proceed the way shown in videoguide See video guide 4 1 Thanks to rigid 3d construction we can finally offer this direct servo drive option You dont need aditional linkage pushrods arms anymore Simply use self tapping screws and included servo arm This option allows rotation of up to 6...

Page 15: ...ing parts shown in the picture below Go ahead and complete both wings sides don t glue them together now Apply CA glue to the contact surfaces marked red in the picture and assemble together then apply the activator Proceed the way shown in videoguide See video guide 4 1 ...

Page 16: ... you can insert the carbon tube spar apply CA glue to the contact surfaces marked red in the picture and insert carbon tube press both sides of the wing together then apply the activator Glue sure bonds small triangle parts to wing joints centerwing ...

Page 17: ...page 17 print your plane www 3DLabPrint com Now apply glue marked red in the picture and assemble together L1B and R1B parts Then glue it to the main wing part ...

Page 18: ...com Now you can slide both ailerons to the main wing hinges and aplly some oil for better movement Glue ailerons parts together Apply CA glue to the contact surfaces marked red in the picture and insert them together then apply the activator ...

Page 19: ...ll servo travel for smaller deflection and so on Asembly proces is quite the same as with option 1 there is only a slight difference in ailerons assembling Proceed the way shown in videoguide Note Asembly proces is quite the same as with option 1 there is only a slight difference in ailerons assembling See video guide 4 1 you will need CA Glue medium or similar medium viscosity CA glue Activator f...

Page 20: ...nd apply oil to the hinges for better movement Proceed the same way as with option 1 for main wing parts there is only a slight difference with ailerons Glue ailerons parts together Apply CA glue to the contact surfaces marked red in the picture and insert them together then apply the activator ...

Page 21: ...ldering Iron or any hot tool 7x 3 5 20mm max 4 25mm self tapping screw for F1 part and cowling nylon nuts and screws or similar 5 6 60 70mm oil vaseline Proceed the way shown in videoguide See video guide 4 3 F8 58g 2 05oz F7 59g 2 08oz F6 69g 2 43oz F5 88g 2 47oz F4 125g 4 4oz F3 204g 7 2oz F2 165g 5 82oz batt cover 23g 0 81oz F1 ann 72g 2 5oz F9 9g 0 32oz cowling 02 66g 2 3oz F_UP3 36g 1 27oz F_...

Page 22: ...fuselage_01_annealing compensated for this effect you can adjust scale exactly for your PLA brand in Simplify3D or any next slicer Proceed the way shown in videoguide See video guide 4 3 Glue the fuselage parts F1 F9 with CA glue together You can use snap knife to clear the shape of printed parts but mostly this is not necessary Glue the sure bonds small triangle parts to the slotes in fuselage F1...

Page 23: ... parts to uselage joints Now you can proceed with next F6 F9 parts there is a bit different coupling system bayonet coupling proceede the way like with wing assembly Apply CA glue to the contact surfaces marked red in the picture and insert them together then apply the activator Now main fuselage is completed ...

Page 24: ...ng parts before is a good idea to prevent gluing block this part Please watch our videoguide at least for this step as this is a bit complicated Glue in to fuselage two nuts for wing screws at first we need to apply few drops of oil vaseline to screws thread and screw it to nut it will avoid glue in to the nut thread Apply CA glue to the contact surfaces marked red in the picture and immediately a...

Page 25: ... as with previous bayonet coupling wing or fuselage system Proceed with fuselage cowling parts 01 and 02 glue it the exactly same way as with previous bayonet coupling wing or fuselage system alternatively you can use Hannes Arch style cowling Cut and remove plastic from internal side of fuselage marked in red use any hot tool ...

Page 26: ...ne www 3DLabPrint com Now all fuselage parts are ready Cut and remove plastic from internal side of fuselage marked in red use any hot tool Cut and remove plastic from internal side of fuselage marked in red use any hot tool ...

Page 27: ...ww 3DLabPrint com Now all main fuselage wing parts are ready Now is time to attach and glue together wing and UP fuselage part Apply CA glue in the edge between wing and UP fuselage parts NOTE don t glue wing with main fuselage ...

Page 28: ...way shown in videoguide See video guide 4 4 You will need CA Glue medium or similar medium viscosity CA glue Activator for CA Glue or similar but gas presurized aerosol is better 9x 3 5 20mm self tapping screws rudder 2 30g 1 06oz H stabilizer RL 45g 1 59oz elevator RL 71g 2 5oz V stabilizer 23g 0 81oz rudder 1 27g 0 95oz rudder 34 55g 1 94oz ...

Page 29: ...ame way like with previous wing parts Go ahead and complete both stabilizer sides and glue them together now Apply CA glue to the contact surfaces marked red in the picture and insert them together then apply the activator Proceed the way shown in videoguide pictures will help you See video guide 4 4 ...

Page 30: ...ne www 3DLabPrint com Well horizontal stabilizer is completed now Both elevators and horizontal stabilizer are done now For elevator proceed the same way like with previous wing parts NOTE do not glue both elevators together ...

Page 31: ...ue to the contact surfaces marked red in the picture and insert them together then apply the activator Rudder 1 cut and remove plastic marked in red use any hot tool For rudder proceed the same way like with previous wing parts RUDDER 2 3 4 NOTE do not glue both Rudder parts together RUDDER 1 ...

Page 32: ...page 32 print your plane www 3DLabPrint com Now tail parts are ready use 9 self tapping screws to complete the whole tail section Do not forget the two screws on the bottom side of horizontal stabilizer ...

Page 33: ...m NOTE apply Loctite thread locker 243 blue to all bolts thread this is very important if you don t want to lose your plane Proceed the way shown in videoguide See video guide 5 1 You will need 2x standard size servo 1 5 12mm self tapping screws any fire source and wire 1 1 5mm hot wire 2x pull pull rudder and elevator system or similar 8x Clevis treaded brass wire end 2mm crimp tube 6 m wire 0 5 ...

Page 34: ...ther side screws Now assemble the pull pull linkage as shown on the picture start with tail side CLEVIS THREADED WIRE END brass WIRE CRIMP TUBE Install the pull pull rudder cables Assemble one end of the linkage by inserting the pull pull cable into one of the aluminum crimp tube through the hole in the brass pull pull fitting and back through the crimp tube Loop the cable backthrough the crimp tu...

Page 35: ...lots in fuselage use any hot wire and included self tapping screws Center servo to its neutral position use your RC system or servo tester Put on prepared servo arms one is suitable for elevator and the other one for rudder you can find this info on both servo arms ...

Page 36: ...both servo arms bolts and all brass ends Now finish pull pull linkage as shown on the picture servo side Note we need light tension in rudder and elevator wires and possibility to tighten up the brass linkage ends in the future When routing the RUDDER pull pull wires linkage through the fuse they should cross like an X but the ELEVATOR should be parallel as shown on the picture Check linkage and a...

Page 37: ...com Of course you can use your trusted solution for rudder and elevator pull pull linkage we just add some pictures to show you some other options Always use some thread locker Loctite and so on and check the function thoroughly on the ground ...

Page 38: ...mple use self tapping screws and included servo arm This option allows rotation of up to 65 degrees and is aerodynamicaly very clear If you use a good quality standard size servos 18 kg this solution is suitable for all flying styles from beginner to 3D extreme experts Proceed the way shown in videoguide See video guide 5 2 You will need 2x standard size servo servo extension cables 300mm 12 inch ...

Page 39: ...pare holes for self tapping screws with hot 1 1 5mm wire then screw this screws in Note you can use more screws you know feeling confident Proceed the way shown in videoguide this pictures will help you See video guide 5 2 Center servo to its neutral position user your RC system or servo tester Attach aileron to axle of servo and again apply Loctite to servo arms bolts then screw it in properly We...

Page 40: ... cheaper servos where you can use full servo travel for smaller deflection and so on You will need 2x standard size servo 2x pushrod total length 96mm axle to axle 4x ball Link 4x suitable bolt washer nut servo arms 4x 1 5 12mm self tapping screws servo extension cables 300mm 12 inch or thicker any fire source and wire 1 1 5mm hot wire Loctite 243 ...

Page 41: ...h two self tapping screws We highly recommend to test the power and function of the ailerons use your hands to load it do not worry to use abrupt power it is better if something goes wrong now Insert servo into slot then prepare holes for four self tapping screws with hot 1 1 5mm wire you can use any steel wire and any source of fire firestarter dremel and so on and screw the four screws in Center...

Page 42: ...n in videoguide See video guide 6 1 You will need Carbon Fiber Landing Gear 170mm or any similar Lightweight Wheel 90 120mm 2pc or any similar 40mm Tail Wheel or printed one or any similar 4mm Steel Axles w M5 Thread or any similar Hex locknuts M5 washers or any similar Landing Gear Wheel Stop Set Collar 9x4 1mm or any similar Landing Gear Wheel Stop Set Collar 6x2 1mm or any similar 6x 3 5 20mm 4...

Page 43: ...will help you See video guide 6 1 Apply CA glue to the contact surfaces marked red in the picture and insert them together then apply the activator Drill 6 symetric holes in carbon LG then attach to LG socket and prepare six holes for self tapping screws with hot 1 1 5mm wire you can use any steel wire and any source of fire firestarter dremel and so on then screw the six screws in ...

Page 44: ...assemble wheelwheel stop collar Now make tail wheel suspension use 2mm wire printed patern will help you achieve the right shape We highly recommend to test the power and function of the tail wheel rudder use your hands to load it do not worry use abrupt power it is better if something goes wrong now ...

Page 45: ...servos or use separate battery See video guide 8 1 You will need 4x 3 40bolt washer M3 nut locknut or Loctite High Performance Setup recommended or similar Motor Xpwr 30CC Motor v2 ESC MEZON 90 120 lite with full telemetry JETI Duplex or CC Battery 2x ZIPPY Flightmax 2650mAh 6S1P 40C in serial 12s or similar weight 2x 421g XT 60 2in1 series adaptor Propeller Mejzlik Propeller 20 x8 E L or any good...

Page 46: ... by adding lead to the nose or tail of the aircraft Make sure the battery is placed properly and secured in position If battery moves during the flight it can shift the center of gravity backwards and the aircraft becomes uncontrollable See video guide 9 1 You will need your own Rx Tx system 9channel adhesive velcro strip for Li Pol battery ESC and Receiver battery strap and zip 2x 1 5 12 18mm sel...

Page 47: ... the CoG a bit backwards Standard CoG is 104mm 4 09in from the Leading Edge of the wing exactly the carbon tube position Plane tuned like this is capable of flying all elements of extreme 3D aerobatics NOTE do not use full deflection at high speed above Va speed especialy ailerons and of course you can use your own values to your liking PLEASE MAKE PRE FLIGHT CHECK motor mount screws ailerons Rudd...

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