How to Make a Rubber Band Powered Helicopter

Welcome to an exciting DIY (Do It Yourself) adventure where I will show you how to building your own rubber band-powered aircraft from the comfort of your own home. This engaging activity is suitable for anyone with an interest in the exciting world of STEM (science, technology, engineering, and math), not just children. I'll walk you through each step, providing a detailed, easy-to-follow instruction utilizing things you probably already have around the house.

Back when I was young, I embarked on this project as a quest for a simple yet exhilarating flying machine. Armed with curiosity and a desire to make something soar, I decided to make my very own rubber band-powered helicopter when the materials for the existing guides were out of reach.

In this comprehensive guide, we'll start by demystifying the inner workings of a rubber band-powered helicopter, and then we'll dive headfirst into the creative process of making your very own. Whether you're a seasoned DIY (Do It Yourself) enthusiast or a complete beginner, this journey promises to be an enjoyable and enlightening experience into the world of STEM (science, technology, engineering, and math) and powered flight.

I am an engineering student who attends Landmark University

Supplies

For the tools you need the following:

A 3D printer (this is optional because I will show you how you can make one without using it)

A pair of pliers

Ruler

Knife, scissor or any tool you can use for cutting(I used a blade for mine)

Pencil (for marking but you can use a pen)

Materials:

For the materials you will need a 3D printer and paperclip but if your like me and you don’t have access to one, then you'll need the following:

Paper clips(x4)

Skewer sticks or chop sticks( I couldn’t get chops sticks so I used skewer sticks)

Popsicle sticks (x1)

Paper or light cardboard (x1)

bead (x1)

Glue (I used superglue)

Tape (you can use any type you have access to but i use black tape so you can see it in the photos)

Pen (x1)

A bowl of slightly hot water

Rubber Bands

Step 1: Understanding How It Works

For those just venturing into the world of STEM (science, technology, engineering, and math), let's explore the fundamental workings of a rubber band-powered helicopter:

 Energy Storage: As you wind the propeller, the rubber band stores energy.

 Energy Release: When the rubber band reaches a particular point, it bursts into action, unraveling itself to release the accumulated energy. The propeller spins as a result of the quick unwinding.

 Friction Minimization: A small bead situated beneath the propeller serves a crucial role—it minimizes friction as the propeller makes contact. This allows for smoother, more efficient movement.

 Aerodynamic Aid: Attached to the frame is a paper or cardboard cutout, strategically designed to create air resistance. This clever addition prevents the helicopter's body from excessive spinning, ensuring that the released energy from the rubber band is effectively harnessed.

 Lift Generation: The spinning propeller, in turn, produces thrust, which creates the lift needed to send the rubber band-powered helicopter soaring into the air.

 In essence, this captivating mechanism brilliantly demonstrates the conversion of potential energy into kinetic energy, culminating in an exhilarating flight experience.

Step 2: Sketching, Planning and Modelling

"Prior to diving into this project, I employed a pencil and ruler to draw out my design plan. As you can see in the accompanying photo, I've provided a clear, dimensioned line diagram that serves as a visual blueprint for the project.

Taking another step, I also made a 3D model using Fusion 360. The Fusion 360 file, conveniently included in this instructable, allows you to explore the possibility of creating a 3D-printed version of this very project. With these valuable resources at your fingertips, you have the power to bring your helicopter to life in a whole new dimension.

If you would like to utilize my Fusion 360 file, either for editing to suit your project or as a helpful reference for your design, you'll find the attached Fusion 360 file with this step. It offers a valuable resource for further customization and innovation. Enjoy your creative journey!

Step 3: Making the Propeller

To make the propeller, The only material you will need is a Popsicle stick. Start by drilling a small hole in the middle of the stick, just large enough for the tip of an unfolded paperclip to pass through. If you don't have a drill, you can create a makeshift hole-making tool by straightening and roughening the tip of a paperclip with pliers.

Next, place the Popsicle stick in a bowl of slightly hot water and let it soak for 30 minutes to an hour. This softens the stick, making it flexible enough to bend into the desired propeller shape. Once soaked, remove the stick from the water, grip it by both ends, and gently twist it to create a curved propeller shape. Maintain this shape for a while until it can't return to its flat state, then allow it to air dry. Once dry, your propeller is ready for action.

If you have access to a 3D printer, you can simplify the process by 3D printing the propeller using the provided STL file attached to this step. Simply load the file into your 3D printer and 3D print the propeller. This offers a convenient alternative for making the propeller.

Step 4: Attaching a Paper Clip to the Helicopter

Begin by using pliers to unfold the paperclip, ensuring it's perfectly straight. Then, using the same pliers, bend the paperclip at a 90-degree angle, leaving approximately 1 cm of straight wire at the end. Next, insert this straight end of the paperclip through the hole in the propeller. To ensure a secure attachment, apply a small amount of glue. This step is crucial as it allows us to create a hook that will hold the rubber band in place later on as we are making the helicopter.

 If your propeller was 3D printed the same process applies for attaching the paperclip

Step 5: Making the Helicopter Frame

Prepare the skewer sticks or chopsticks by measuring and cutting them to a length of 170mm. If you're using skewer sticks, measure from the blunt end and trim the sharp end as excess. Repeat this step with another stick of the same length. Secure the two sticks together with tape (any type will do; black tape is used in the photo for visibility). This taping is temporary and helps keep the sticks in position while you apply glue to permanently bond them. Once the glue dries, remove the tape and apply glue to the previously taped areas.

Next, disassemble a pen, keeping only the ink tube. Cut approximately 1.5 cm from an empty pen ink tube (ensure it's completely empty; otherwise, cut out an ink-free section if needed). Straighten another paperclip, which will be used to hold the ink tube about 1 cm away from the glued skewer stick or chopstick. Wrap one end of the paperclip around the ink tube and the other end around the glued skewer stick or chopstick, leaving about a 1 cm gap between the ink tube and the sticks. Create a hook using yet another paperclip and attach it to the bottom of the glued stick.

Optionally, for this step, you can 3D print the frame of the rubber band-powered helicopter using the provided file that is attached with this step.

Step 6: Assembling the Helicopter

Follow the Image as a Guide

Begin by referencing the accompanying image for visual guidance. Start by threading the bead onto the straightened paperclip, which was previously attached to the propeller. Next, insert both the propeller, ensuring the bead is in place, through the ink tube located on the frame. Shape the end of the straightened paperclip (attached to the propeller) into a hook-like form. Finally, secure a piece of paper or lightweight cardboard to the helicopter's frame. Congratulations, your rubber band-powered helicopter is now COMPLETE!

Step 7: Take Flight

With your helicopter fully assembled, it’s time for its first flight.

To launch your rubber band-powered helicopter, first, insert your rubber bands between the two hooks. Begin by winding the propeller until it has stored a sufficient amount of energy. Then, with a gentle release, set the propeller spinning, and watch in awe as your helicopter gracefully takes flight, soaring through the air with remarkable ease. Enjoy your aerial adventure!