A group of 3D printing enthusiasts, tech lovers, and sci-fi fans recently came together to design a unique spherical UAV for a local mechanical design competition. The main challenge was to create something that looked "unusual," and this team certainly delivered. They documented their entire process, from the materials needed to the STL files, on Instructables, making it easy for others to follow along or build their own versions.
The aircraft draws inspiration from various science fiction sources, including the sleek flying machines in *Prometheus*, the glowing orb from *Stargate*, and the iconic Star Wars droid, the IT-O Challenger. While they explored many different ideas, they ultimately focused on these influences to shape the final design.
After deciding on the direction, the team studied existing spherical drone technologies, such as the Japanese Defense Ministry's spherical flying car and the Gimball, known for its collision avoidance system. They also looked into remote-controlled toys with similar cage-like structures. However, they noticed issues with airflow in those designs and aimed to improve upon them.
"We chose a coaxial counter-rotating rotor system, which allows us to control the direction of the aircraft by adjusting the speed of the propellers," the team explained. This setup gives them better maneuverability and stability.
To manage airflow, they designed a custom intake system. Air enters through the bottom and is directed through four output tubes, exiting on one side of the sphere. For propulsion, they placed the heaviest components—like the battery—under a spherical cage. This strategic placement ensures the center of gravity remains stable, allowing the aircraft to adjust itself and move in the opposite direction when needed.
Many parts of the aircraft were 3D printed using ABS plastic, including the intake manifold, airflow diverter, and output manifold. Other components were made from laser-cut paper laminate foam, combining strength with lightweight construction.
This project not only showcases creativity but also highlights how real-world engineering can be inspired by imagination. Whether you're a hobbyist or a professional, there's a lot to learn from this innovative approach to drone design.
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