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User Guide rev. 2016/11

Fully 3d printable

Zivko Edge 540 v3 Hannes Arch replica

wingspan 1187mm (46.7in)

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Zivko EDGE 540v3 Hannes Arch relica – fully

printable R/C plane for your desktop 3Dprinter
Future of flying - Print your own plane

We still trying move things further, so this project is again full of other improvements for
better durability , easier assembly , better geometry solution and so on..., we hope you en-
joy it, although this print may test your competencies to and quality of your printer
(welcome to the thin wall printing)

The first fully printable airplanes with suitable files prepared for your 3Dprinter.
Flight charecteristics are comparable or even better than classic build model airplane.
Simply download and then print it anytime you need only for $18 (filament cost).
This is not a dream, now you can print this HI-TECH …. at home, print spar parts, and so on...

Extensive hi-tech 3d structural reinforcement which makes the

model very rigid while still maintaining lightweight airframe and exact airfoil even when it
is made only from plastic. This perfect and exact 3d structure is possible only due to aditive
3dprinting technology. So welcome to the 21th century of model flying. Be The first at your
airfield.

Easy to assembly, you do not need any extra tool or hardware, you only need to
glue printed parts together and make pushrods for control. The rest of the assembly is very
easy.Simply add brushless motor, ESC, servos and radio system. Don´t worry, detailed step
by step PDF/VIDEO is included.
You will get superb performance airplane with High efficient powerplant which let you fly
7+ minutes at full throtle with the speed exceeding 165kph (HP setup). On the other hand
low stall speed is achived for easy landing.

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General specifications (HP setup):

Lenght: 1048mm (41.0in)
Wingspan: 1187mm (46.7.1in)
Height: 368mm (14.5in)
Wing area: 23.0 dm2
Wing loading: 48.6 g/dm2
Airfoil: NACA sym. modificated
Print weight: 730g
Empty weight (w/o battery): 910g
Takeoff weight (6s 1300 lipo): 1120g
Max takeoff weight: 1300g
Never exceed speed, VNE: 205 km/h
Design maneuvering speed, VA: 165km/h
Stall speed, VS: 30 km/h

Powerplant
Propeller: aeronaut ELP 11/5 or APC 9/6 - 11/5.5
Motor: AX-4008Q/620KV
ESC: Castle Creations TALON 25
Battery: Turnigy nanotech 1300 mAh/6s/22.2V, 216g, 45C

Performance measurment

Max speed VH (level flight): 105 km/h – 56.7kn – 65.2mph with APC 9/6

Rate of climb: 20 m/s (5 373 ft/min) with APC 9/6

Flight time (3s 3000mAh/full): 7:40 with APC 9/6

5:30 with APC 9/7.5
7:40 with aeronaut ELP 9/6

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Zivko Edge 540v3 , History

The Edge 540, manufactured by Zivko Aeronautics, is as precise and controllable as it is
aggressive. The small, one-seater aircraft is a favourite amongst Red Bull Air Race pilots,
largely due to its fuselage.
The computer optimised, steel tube frame makes the Edge 540 an extremely light, very
durable and easily repairable raceplane.
Using an unconventional straight-edged wing, the Edge 540 sparked much interest in flying
circles around the world, particularly after Kirby Chambliss began using it for aerobatic
competitions. The aircraft has since evolved into the highly refined and technologically
advanced version of the original prototype, with the radical wing now acknowledged as a
pioneering feat of design.

Hannes Arch
Hannes Arch was one of the most successful pilots in the history of the Red Bull Air Race. Up
until the 2015 season Arch finished first or second overall in the last four World Championships.
The first European to win the title in 2008, Arch was a creative force who pushed the world’s
fastest motorsport forward with innovative tactics and technology. Fiercely competitive, he
was an accomplished adventurer who had climbed most of the world’s highest mountains
and thrown himself off many cliffs as a BASE jumper. The Austrian’s fighting spirit made the
last four Red Bull Air Race Championships thrilling battles to the final and with 11 victories
he was second on the all-time race wins list. He won the 2008 title in only his second season
with a determined and fearless style of flying that shook up his rivals and forever changed the
dynamic of the sport.
Arch began flying at 16 after obtaining a Special Pilot’s Licence in his native Austria. He first
focused on hang gliding and at 19 became a state-approved mountain and ski guide. At one
point, Arch was also ranked as one of the world’s best mountaineers and climbers. He studied
Sports Science and worked as a lecturer on sport climbing at Graz University but left just before
finishing to focus on his flying passion. He became an accomplished paragliding test pilot and
is credited with being one of the world’s first “aerobatic paragliders.” He began experimenting
with aerobatics in 1998 after making the crossover from free flying to motorised flying and
joined the Swiss National Aerobatic Team.
Arch made an indelible mark on the paragliding scene by organising a gruelling international
competition that has become the popular Red Bull X-Alps event. He also made some of the
most spectacular BASE jumps ever. He and Ueli Gegenschatz became the first to jump off the
imposing 1800 metre north face of the Eiger, one of the most daunting Alpine peaks. In 2003
they became the first BASE jumpers to conquer the north face of the Matterhorn. Arch began
performing in air shows across Europe in 2003.
His raw talent, determination and skill propelled him to become the European Aerobatic
Champion in 2006 and he joined the Red Bull Air Race a year later in 2007, where he promptly
became rookie of the year. Arch was born in Trofaiach, Austria and lived in Salzburg.

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Included:
1.STL 3d files
universal STL files designed for use with desktop FMD 3d printers and slicer software as
Simplify3D (recommend) CURA or MatterControl (this STLs are not compatible with Slic3r).

2.Factory files for Simplify3D slicer

with all our setting, this Factory files included all you need, note: we use PRUSA i3 ORIGINAL
printers so you may need adjust the basic printing parameters to match your printer or use it

as a start point for you, please give a look to Simplify3D

3.Step By Step PDF/VIDEO userguides
Apart from this userguide, please give a look to the Printing Guide with some Tips and Advices
for airplane printing (Thin Wall Printing)

4.Gcodes
Basic Gcodes prepared for direct use, so universal as is possible. Should work with i3 style
printers, you can try it out, but We can not guarantee that it will work with your printer.

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100% works with PRUSA i3 ORIGINAL 3d printers...

5.Prepared settings for CURA and MatterControl slicers

If you dont like Simplify3D for any reason, there is always possibility to use another free slicer

you can use our basic setting (setting files) as a start point and edit it as you need.

6.Scale markings PDF

Let print on thin adhesive foil and place on the model as needed, violet cut lines included...

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1048mm (41.0in)

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1187mm (46.7in)

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Step By Step PDF/VIDEO userguide

1. Choose airplane at www.3Dlabprint.com, our Facebook for live information...
Basic requirments (P-38 Lightning):
min volume 195/195/150mm (250/120/150)
nozzle 0.4mm recommended (0.35 or 0.5mm alternatively)
Heated Bed recommended
PLA filament (or PETG, APLA, htPLA, PC-max....) not ABS
If you feel a little bit confused you can download wing test
part from our websites or thingiverse, (the biggest part). Or
contact [email protected]
It is good idea to print LG legs from PETG (more flexible)
2. Create account, download
You will get download link for all files to your email (zipped)or you can log in to your ac-
count and download directly from our websites.

3. Gcodes preparing
options A Gcodes:
if your printer is i3 comptatible you can directly use prepared gcodes, simply save each to
SD card and let 3d printer do his job, HE temperature is set to 230 for best layer bonding,
you can edit speed and temperature on your printer LCD only. If Gcodes does not work
please proceed to the next options.

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options B Factory files Simplify3D (recommended)

We prepare all you need in this files (basic FFF, parts arranged and so on...)
You can use this our setting as a start point and edit it as you need (adapt it for your printer),
print only parts you need and so on... On moust 3d printers it should work as it is, but please
give a look to the setting and edit it if is different to your printer, we are not liable for dam-
ages resulting from the use of our settings. If this does not work please proceed to the next
option.

options C Simplify3D manual setting (watch and learn)

Use our video guide 2 for proper setting... this is very good option and you will learn a lot
about Simplify3D and become an 3d expert. Of course you spend a lot of time and youtube
pause button will become your friend.

AND... please give a look to VideoGuides:

video 2 Simplify3D setting

video about Thin Wall Printing

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options D CURA or MatterControl

MatterControl and CURA are free :-) and also gives very good results and airframe is still
strong enough, slicer setting is very easy.
Please try find right extrusion multiplier and temperature for good weight and bets layer
bonding, give a look to parts weight list for proper multiplier setting.

You can also use our predefined CURA or MC slicer setting file included in package (always
adapt it for your printer, change build volume, filament diameter and so on... depends on
your printer!!!):

CURA_wing_fuse.ini (wing, fuselage, battery holder parts)

CURA_ailer_elev.ini (only ailerons, elevator and rudder parts)
CURA_thick.ini (motor mount, spinner)
CURA_wing_tip.ini (only wing tip)
OR
MC_wing_fuse.slice (wing, fuselage, battery holder parts)
MC_ailer_elev.slice (only ailerons, elevator and rudder parts)
MC_thick.slice (motor mount, spinner)
MC_wing_tip.slice (only wing tip)

AND... please give a look to VideoGuides:

video CURA slicer setting

video CMatterControl slicer setting

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4. Print it
Save generated Gcodes and insert SD card to your printer, prepare your printer and start
printing, we prefer to use SD than direct connection via USB Note: ABS filament is not suit-
able for this...
Scaling the model will lead to unusable result!
video guide about printing
you will need: PLA filament - good quality and strong PLA (we need good layer bonding)
Strong hair spray (or your favorite adhesive bed surface)
Razor blade
It is good idea to print LG legs from PETG (more flexible)...

AND... please give a look to VideoGuides:

video printing guide

Main parts weight list:

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Basic Typs and Advices

Plese Experiment with your extrusion multiplier...
Also HotEnd temperature is very important for strong result, please try increase tempera-
ture to find the best value (200 up to 260 celsius)
Turn OFF cooling fan for better layer adhesion (HE fan of course ON) we dont need it for
our thin wall printing...
We try lot of filaments and so far PLA is still the best for our models (2016).
You can try aslo PETG and PC-max from polymaker is very promising filament.

HEATED BED is very recommended, 60-70celsius (print without warping ends)

Looks like any standard quality PLA is OK for our planes, BUT it always depends on combi-
nation PLA vs. Extruder vs. HotEnd.
We find that some color of filament has lower layer adhesion also.
Nowadays there is lot of 3dprinters on the market, very most of them is OK for printing our
aircrafts (specific thin wall printing...) suficient volume, heated bed, 0.4mm nozzle.

Please give a look to Printing Guide:

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5. Assembling printed parts

5.1 Wing assembling
Glue wing parts with CAglue together, use activator and instal ailerons...
See video guide #4
you will need: Steel wire/pushrod, diameter 1.0mm
Carbon rod, diameter 1.0mm
CA Glue - medium or similar medium viscosity CA glue
Activator for CA Glue or similar, but not-mechanical is better
Snap knife

5.2 Fuselage assembling

Glue with CAglue fuselage parts together, use activator, instal elevator and so on...
Glue on LG legs to fuselage...
See video guide #5
See video guide #5_1
you will need: Steel wire/pushrod, diameter 1.0mm
Carbon rod, diameter 1.0mm
CA Glue - medium or similar medium viscosity CA glue
Activator for CA Glue or similar, but not mechanical is better
Snap knife or Sandpaper
Soldering Iron or any hot tool
Main and Tail wheel (50-60mm and 20-30mm)

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6. R/C equipment

6.1 motor setup

HIGH PERFORMANCE SETUP (recommended) propeller 11/5.5:
See video guide #6 (for HP setup)
you will need: Motor – AX-4008Q-620KV
Speed controler (ESC) – CC Talon 25 or similar 30-40A/6s
3x PAIRS, 3.5mm Gold Connectors - optional
Battery 1300mAh/6s up to 2200/6s or 2x 1300-2200/3s, better (use 2to1 seri
al connector)
Note: bigger battery leads to nose heavier plane which is more stable and
easier to control... (for firts 10mm forward from CG tags, never aft)
Male XT60 connector
Shrink Tube black
Solder wire and Soldering Iron
Hands free Holder - optional
printed motor mount (25/25)

ECO PERFORMANCE SETUP(spent only 30 bucks without any soldering)prop 11/5.5:

you will need: Turnigy D3530/14 1100KV or similar 3530-35 1100kv
40A Electronic Speed Controller or similar 40Amps
Turnigy 2700mAh 3S 20C or similar 2200-3800/3s
Note: bigger battery leads to nose heavier plane which is more stable and
easier to control... (for first 10mm forward from CG tags, never aft)
printed motor mount, find the one which fits... (25/19)

6.2 servos
Test and center all servos with servo tester or transmitter, then instal horns in midle posi-
tion and cut wing Servos mount... use HXT900 or any 21x21x23mm
See video guide #7
you will need: 4x 9g Servo HXT900
2x Servo Lead Extension or similar
Snap knife
Soldering Iron or Small handsaw or Dremel

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7. R/C Equipment installing

Instal prepared RC equipment: Motor, ESC, Servos. Made steel pushrod for ailerons, eleva-
tor, rudder and connect within servo arms...
Nose and motor mount are already in angle for compensating rotating propeller stream.
See video guide #8
you will need: Steel pushrod, diameter 1.0mm
Pliers and optionaly Z Pliers
Printed motor mount, find the one that fits for your motor...
4x Screw 3/12mm depends on motor-mount
Small screwdriver+
Your earlier prepared R/C equipment
3x Self Tapping Screw M3x8mm or similar

8. Decals/Marking
Print pdf decal sheat to adhesive foil (pdf already include violet cut lines for cut machine)
Apply to airplane surface...
See video guide #9
you will need: PDF scale markings printed to adhesive foil
Snap knife

9. Finalization
Instal your reciever, connect batery, setup servos and etc. with your trasmitter, lock servo
position, then instal propeller...
!!!Make sure that the battery is placed properly and secured with wing battery holder, if
battery moves during flight it can shifts the center of gravity backwards and aircraft will be
uncontrollable!!!
See video guide #10
you will need: Your own Rx/Tx system
Battery for your setup...
Foam strip for Li-Pol battery
Printed spinner
Propeller + printed spinner (use 9-12/4-6 depends on your setup and
needs)
Small screwdriver+
CA Glue - medium + activator
!!!Never set ESC with instaled propeller, this is very dangerous!!!

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10. Go flying
Before flight check: center of gravity is very important (move it forward 10mm for the first
flights see CG markings and chapter 11 bellow), battery properly charged, ailerons and ele-
vator deflection check, your own flying skills or RC simulator training...
Accelerate gradually and keep the direction during taxiing by using the rudder, try it first
without taking off a few times ( taxiing on the runway ) Then gain speed until the plane
move up tail part , then pull the elevator gently and you’re in the air.

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11.Pilots Please Attention!!!

For the first flights we recommend set center of gravity of the airplane by about 10 mm for-
ward of the CG tag - nose heavy, this increases the stability (you can use heavier battery).
Also you can decrease elevator and ailerons deflection.
Make sure the battery is well fixed in proper possition if it moves during flight it will cause
move CoG aft and will lead to uncontrolable flight behavior...

You can then return to the center of gravity (balance aircraft)the CoG points and expo set to
60 % as stated in the video/instructions... this gain back extra maneuverability when you will
be sure with flying your airplane.

!!!Never fly aft positioned CoG!!!

And Please, use this files only for your own purpose, do not
send further... Thank you very much

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