The Falcon: 150+ Foot Range, Best in Class Performance Glider for the Pro User

Overview

Almost none of the top gliders can match the stability, accuracy, and range of the Falcon. Not only is the center of gravity engineered for stable flight, but also the orientation and layer count in the wings is designed to control warping to create an airfoil.

PA-CF is the very best material for this glider because it has the durability the rigidity, and the warping characteristics perfect for this glider. PETG, ABS, ASA, PC, and PA will also work. The Falcon has been designed to be rubber band launched . It will not hand launch. If using standard size rubber bands use 3 to 8 bands. If you have XL industrial size bands or shock cord use that.

If printed in PETG or PLA the glider will not have a strong airfoil on the wings. Tuning still allows for great flight, but accuracy will be reduced. PLA will shatter with minimal impact while PETG will only shatter with significant impact. If ASA or ABS is used the glider will not shatter easily, but under 40+ mph impact there will be stress marks from the impact. Over the course of 10+ crashes at super high speed those stressed areas will break.

How to Print (crucial)

• 30% gyroid infill

• 4 perimeters

• First layer oriented parallel to the wingspan (look at the photo).

• Supports on build plate. 

If the glider does not have the correct orientation wing loading and bending will be asymmetric in flight which will more than half the distance and accuracy. I beg you to use the orientation shown in the photo!

How to Tune (critical)

Normal Tuning Advice:

Bend the tail fins into a V shape as shown in the photo. In order for this to be done properly heat is required to set the fin shape. Aim to match the third to last photo.

Bend the wings upward slightly aiming to match my photos.

Bend the spine upward to use the V tail as up elevator as shown in the second to last photo. The more you bend the more the glider will angle up. Comment if your glider is not flying right and I will be right there to help. I monitor the comments very regularly and will give prompt advice.

Advice for tuning low warping filaments like PETG:

You must bend the tips of the wings slightly to create an airfoil for the plane to fly properly. The sign that this step is needed is that the plane will roll slightly during flight. The plane may also roll a lot (think one or multiple barrel rolls). This amount of rolling is a sign that the tuning or warping is very bad. If any of this is confusing then write a quick comment and I will address your issue.

Testing:

I have clocked the Falcon going 63.3 mph (+ or - 5mph) using a test where I measure the time to cross a fixed distance. I measure the time in intervals of 0.01 seconds so that is where the error comes from. 

The Falcon is accurate enough to hit a 2 foot target at a distance of 40 feet reliably. 

The Falcon should be able to fly more than 150 feet with proper tuning and rubber bands.

The Falcon has undergone impact testing at 60 mph directly into the ground. If launching on grass it can withstand more, but it is hard to draw enough rubber bands to reach over 60 mph. If launching on concrete or asphalt it should be able to withstand any crash within the normal flight speeds.

Design Principles (no need to read this)

Center of Gravity and Elevator

The center of gravity is the most crucial design aspect on any glider. Often popular gliders position the center of gravity too forward causing the glider to fly a bit more like a rock than a plane. To correct for this excessive up elevator is needed. The Falcon uses a larger tail for up elevator and a more balenced center of gravity. This reduces the amount of up elevator needed for steady flight and increases impulse/energy ratio that the up elevator provides. The result is both reduced drag and a much broader range of optimal speeds.

Orientation and Wing Loading

The Falcon a better orientation on the build plate which causes symmetrical loading of the wings during flight, and symmetrical bending of the wings. Other gliders do not orient the wingspan parallel to the first layer lines, causing asymmetrical loading and bending. 

Rubber Band Hook and Pull Tab

The Falcon has a larger rubber band notch which allows for much more powerful bands or more bands than other gliders of the same weight class. The larger rubber band notch creates more of a weak spot, which the Falcon counteracts by both increasing the size of the head around the rubber band notch and then balancing the plane with a pull tab at the back of the glider.

The Falcon includes a pull tab at the back of the glider to allow for more easy tensioning of the rubber bands. Instead of placing your fingers on the back fins of the glider and messing with the tuning you are able to draw the glider back by the pull tab. I have not found any other gliders that use this feature. Please comment if you have found one, I would love to check it out.

Airfoil and Intensional Warping

Finally the Falcon prints great in filaments that tend to warp, because the exact wing geometry, layer count, and orientation causes the wings to warp into the shape of a perfect airfoil. If the wings of your glider warped when taking it off the build plate, then great, they were supposed to warp a little. If you look closely at my photos you can see the warping. Not only does the warping create an airfoil but it also stiffens the wings in the vertical direction for more stability during flight and allows for easy deflection during crashes directly on the wing.