Tesla Tech 2025
Albuquerque, NM
August 6 – 10
Tesla Tech 2025 Program Link
Live Streaming signup for Tesla Tech 2025. Link
Drone Workshop (Tesla Tech 2025)
Wednesday 1:00 PM
Build Guide
Parametric Connector Design for 3D printing Link
A very useful OpenSCAD program script that generates stick connectors with varying number of arms at varying angles. These connectors can be 3D printed. This makes possible construction of custom stick frames.
The Terrence Howard Lynchpin drone design has a frame of connected rods or sticks.
Terrence Howard Lynchpin drone frame kit. View
Terrence Howard Lynchpin drone competition. View
Terrence Howard Lynchpin drone video. View
Very interesting linking/pinning together of multiple drones.
DEMO Reel Tangential Flight Corp. View
Omnicopter flight video. View
Joe Rogan – Terrance Howard podcast: View
Practical Drone Frame Prototyping
Low-cost sticks View
Be aware that there is no specification for the the diameter of a “bamboo skewer”, and tolerances are loose. Therefore, order one large batch of low-cost sticks to provide an inventory with a known diameter. And then adjust the 3D printable connector to fit.
For strength, impregnate the bamboo skewers with thinned polyurethane marine grade varnish. View
Technical data for polyurethane marine grade varnish. View
(Note: Follow safe use of volatile hydrocarbons.)
Thinner View.
Practical Drone Panel Prototyping (Wings)
Greenhouse polycarbonate panels. View
UV curable ABS-like resin. View
Resin thinner/cleanup. View
To increase strength, insert resin dipped bamboo skewers in corrugation vanes.
UV light for curing resin. (Quantity 2 recommended.) View
2 mil thick aluminized mylar reflecting roll for UV curing. View
Thin aluminized mylar reflecting blanket for UV curing. View
Wing panels can be laser cut, milled out, or cut with water jet. Laser cutting is preferable. Milling can leave rough edges. Water jet cutting works reasonably well.
For laser cutting (preferred), diode lasers don’t work for polycarbonate panels. A CO2 laser works. Ventilation is required. View
Duct tape and glue work for attachment of a wing stiffener to a wing panel.
Duct tape. View
Glue. View
CAD for 3D Design and Printing
Powerful yet low-cost CAD makes 3D design possible. Options exist which are free, minimal cost, and reasonably priced for high-level capability.
Onshape is a full-capability CAD package. The free option only allows saving files in a public library so that the work is not private. This is sufficient for learning and training. The professional version that allows saving of private proprietary files costs $1500 which can be worth it for professional work. View
SolidWorks offers a full-capability CAD package with a personal use option that costs $48/year. View
The option for professional use costs $2820/year. View
AutoDesk Fusion 360 offers a free limited version which some say is not worth the time learning because of the constraints. The full professional version is a comprehensive CAD package that costs $680/year. View
Public domain slicer programs are available for free. Several of these free programs have limited CAD capability which can be sufficient for simple 3D CAD design These programs generate the GCODE from CAD files for 3D printing. One of the best slicer programs is PrusaSlicer. View
A slicer program can create a hollow fill to reduce weight. For large solid bodies, a fill of only 15% – 20% can form a very light, yet strong, part. See
OpenSCAD is a free program that generates CAD files with a scripting language. View
Writing a 3D model as a programmed script can have a steep learning curve, but many scripts are available for download online. Also, AI can generate programmed scripts. For instructions on how to do this, prompt your favorite AI Chat: “I want AI to write an OpenSCAD script for me. Please provide instructions on how to do this.”
As already presented, there is a programmed script for generating stick connectors that works well for building prototype frames. View
3D Printing
It is amazing what prototyping and even low-volume production can be done with 3D printers now. The cost of an entry level 3D printer is very low, but 3D printed parts can be ordered from a prototyping service. See
A good manufacturer of entry-level and advanced 3D printers is AnyCubic. It is amazing what can be purchased for $200. View
A good manufacturer of high-end 3D printers is Bambu Labs. View
AnyCubic has a very good maker community with thousands of downloadable files. View
Bambu Labs also has an excellent maker community. View
Thingiverse is a leading maker community with millions of downloadable files. View
There are hundreds of choices for 3D printing filaments. A very common and easy-to-use filament is PLA. See
Although PLA is one of the most common filaments, it is not recommended for a drone because it has a low melting point. Parts made with PLA can warp or melt if set on a car dash during a hot sunny day.
PETG filament is tough, less brittle, and has a higher melting temperature compared to PLA. It is more stringy during printing, though. For simple parts, the stringing can be easily removed. See
PolyLite PLA and PolyLite PETG have porosity that decreases the weight of the material. The porosity makes it possible to impregnate parts with thinned polyurethane marine grade varnish (previously mentioned), and this increases the strength and reduces warping due to heat. See
Flight Control and Electronics
The scope of an approximately 4-hour drone workshop is limited, and there is insufficient time to address the flight control and electronics. The Build Guide provides some information as do the four following links. However, AsymWar LLC is in the process of forming a community to design, build, test, and train with drones. Come join us!
QGroundControl is a good program for flight control, and it is available for free download. See
SpeedyBee is a leading supplier of flight control electronics. See
Receiver and radio controller. Please note that the receiver and radio controller must be matched. See this and this.
FPV camera and goggles. Please note that the camera, video transmitter, and goggles must be matched. See