High School Aerospace Research & Development Club
Welcome to Waco Aero, a student-led aerospace research and development club dedicated to hands-on learning in aviation, rocketry, and aerospace engineering. Our members design, build, and test aircraft, conduct materials research, and explore the fascinating world of flight.
Founded in 2025, our club brings together students passionate about aerospace to collaborate on real-world engineering projects. We believe in learning by doing, rigorous testing, and thorough documentation of our findings.
To inspire the next generation of aerospace engineers through practical experience, collaborative research, and innovative design projects.
3D Printed RC Aircraft (January - March 2025)
Our inaugural project involves designing, printing, and flying a remote-controlled aircraft using 3D printing technology. We're documenting everything from filament selection to flight characteristics to share our findings with the maker and aerospace communities.
Our club conducts systematic research on materials, manufacturing techniques, and flight performance. All findings are documented and published here for the aerospace maker community.
Objective: Compare the strength-to-weight ratio and flexibility of PLA and PETG filaments for wing construction.
Methodology: Printed identical wing ribs using both materials at 0.2mm layer height, 20% infill. Conducted three-point bend tests and weighed samples.
Results: PETG showed 23% greater flexibility before failure, while PLA was 8% lighter. PLA exhibited better layer adhesion at standard print temperatures.
Conclusion: For our application, PLA is recommended for wing ribs due to weight savings and adequate strength. PETG may be preferred for high-stress components.
Objective: Determine the optimal print orientation to maximize fuselage structural integrity.
Findings: Research in progress. Initial tests suggest vertical orientation provides best results for cylindrical sections.
| Material | Layer Height | Infill % | Weight (g) | Break Force (N) |
|---|---|---|---|---|
| PLA | 0.2mm | 20% | 45.2 | 182 |
| PETG | 0.2mm | 20% | 49.1 | 224 |
| PLA | 0.3mm | 20% | 44.8 | 168 |
Explore our completed and ongoing aerospace projects.
Status: In Progress
Our first club project - a fully 3D printed RC aircraft with 1.2m wingspan. Designed for stable flight characteristics ideal for beginners.
Timeline: January - March 2025
Status: Testing Phase
Comparing different airfoil profiles and construction methods to optimize lift-to-drag ratio.
Airfoils Tested: Clark Y, NACA 2412
Status: Planned
Planned for Spring 2025 - model rocket design and construction with emphasis on recovery systems.
Helpful resources for aerospace enthusiasts and makers.
Meet the students driving innovation at Waco Aero.
Club Founder & President
Passionate about aerospace engineering and 3D printing technology.
Lead Designer
CAD specialist focused on aerodynamic optimization.
Electronics Team
Handles flight controllers, motors, and power systems.
Test Pilot
Experienced RC pilot managing flight testing operations.
Research Coordinator
Documents testing procedures and analyzes data.
Manufacturing Lead
Manages 3D printing operations and quality control.
Interested in joining Waco Aero? We meet every Tuesday and Thursday after school in Room 205. All students welcome, no prior experience required!
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