Streamlined fairings: extruded vs 3d printed

[Brock]

I'm going to be using streamlined struts on my LEXL, there are just too many reasons for it.  Question is, since I already have the four 1-1/4" tubes, do I purchase the Carlson struts or do I go a different direction.

Different direction is kinda my modus operandi, so I'm looking into 3D printing fairings for the struts.  I've done this before with great success so this should be easy.

First I did some weight calculations and learned that the Carlson struts add 6.7 lbs to the total build (pic).  That's an increase of .257 lbs/ft over round. Then playing around with the printer and my scaled down (to 1-1/4") fairing model I was able to print and discover it's possible to print fairings at .225 lbs/ft.

So then I just orderd some LW-PLA which is foaming low density material use for making flying model planes.  I'll report back when I have more information.

[pappyadkins]

I plan to do the same for my struts, with a little different lighter weight design... I would also like to try Lightweight PLA, but I have a question about it for sure... what happens in the heat of the day??? I know PLA will NOT hold up... it will warp... I made a 3d rib jig design & printed in PLA just as a prototype... while we was at the UL Georgia flyin (not even too hot) it warped on me... just curious about the LW PLA for the same reasons... BTW, what type of printer do you have?

[Brock]

I share your concern about PLA & heat/UV.  Fortunaltely, if this does not workout then I'll have a roll of the stuff to make paper(plastic) airplanes with the grand-kids.  I did see that there is a LW-ASA available.  So that would be my next try.

Printer here is a Bambu X1C.  It's my second printer, sure makes things easy compared to my first printer.  Here is a vid of the fairing print.

[Fairing Print]

[pappyadkins]

Yes, let us know for sure... I was thinking of trying the same thing (I believe we can streamline our round struts easy & lightweight), so I was exited to see this post... I have the Bambu P1S - and I haven't had good luck with regular ASA... (I bought it to try the RigJig - but not any luck, haven't given up - just other obligations...)

[Brock]

Hmmm I had no trouble with ASA.  I had printed brackets to put louvers on the roof of my sunroom.  Brackets were fine if handled carefully. 
is a really nice comparison video of LW-PLA vs LW-ASA vs PLA.

[pappyadkins]

Nice video, thanks... Yeah a friend of mine didn't either, but has problems with ABS (I typically don't) - we are flipflopped on the 2... We both have Bambu P1S...

[Brock]

Tried them on for a test fit.  Like a glove.  Also, amazon man dropped off the roll of LW-PLA today.
[Here] is a thread I've been reading to get me started.