FROM DESIGN TO BUILD

Source the whole build.

Parts, paper, hardware, filament and tools belong in the plan. Start with a family below; your Design Lab and Studio views show requirements for your exact choices.

These are starter examples. For a downloaded revision, follow its BOM.md specifications and cut lengths; do not replace them with the baseline dimensions on this page.

Folded airplanes · paper only

Use one uncoated US Letter sheet, 8½ × 11 inches, at your selected 75 g/m² weight.

Paper source: HP Office20 · US Letter · 75 g/m² · 500 sheets at Staples. Confirm delivery and availability for your address before buying.

Check the package for the sheet size and weight. No other materials are needed.

Explore paper designs →

Fold · paper-wing bench study

Starter baseline · experimental · check your saved design before purchasing.

3D-printed supports, with paper covering.

The next Fold revision is planned around lightweight 3D-printed wing supports: ribs, leading and trailing members, root reinforcement, and a positive connection to the center fitting. Part geometry, filament, print orientation, joints, measured mass and balance must be developed and tested together.

The AMA Wright Stuff construction guide illustrates how a frame supports a light covering. The NASA-hosted McEagle glider provides another reference for wing attachment and alignment. These inform the structural review; their materials and trim settings do not qualify a printed FlightHub design.

Existing Fold files remain available for inspection and bench experiments. They contain the original unsupported wing, not the proposed frame.

Materials & sources10 requirements · current design

Gather the supplied components as well as the printed parts. Quantities below are for one build; store packs may contain much more. Reuse tools and printer access you already have.

Match the listed size and material before buying. Check current stock and delivery at the store; FlightHub does not show live prices or inventory. Linked parts still need fit checks in your build.

Components you supply

  • Wing, tailplane and fin paper

    1 A4 or US Letter sheet + spare sheets

    300 mm template; paper weight 80 g/m²

    Nuburi A4 printer paper, 40 sheets Amazon marketplace · specification reviewed 2026-09-28

    A4, 80 g/m²; 40 sheets

    Listing specification matches the 80 g/m² A4 Fold template. Print at actual size and check the 50 mm scale bar; paper mass and stiffness are unmeasured.
    Prepare & check

    Print the matching PDF at 100% / actual size; check the 50 mm scale bar. Cut the two wing halves, tailplane and fin. Join the 5 mm root overlap before forming the wing. Use the preparation steps below.

  • Straw boom — supplied, not printed

    1

    4 mm outside diameter; one straight length cut to 210 mm

    Pitsco Art Straws for Structures Pitsco Education · specification reviewed 2026-09-28

    Unwaxed paper tube, nominal 4 mm diameter × 16 in length; box of 1,800

    Dimensional candidate only. Measure actual outside diameter, cut to the saved boom length, and check mass, stiffness and fitting clearance. The bulk box may be impractical for one build.
    Prepare & check

    Measure outside diameter with calipers and dry-fit all three fittings. If the stock differs, change the straw diameter in Studio and save a new revision before printing. Material stiffness and mass also need checking.

    Before building: The linked paper tube matches nominal dimensions only. Its mass, stiffness and fit have not been tested on this design. A tested retail boom is still needed.

Filament and consumables

  • Tape and retained trim

    Tape as needed; trim amount not established

    Use the supplied build guide; exact mass and placement are not specified

    Scotch Magic Tape with dispensers, 3 rolls Staples · specification reviewed 2026-09-28

    3/4 in × 300 in matte-finish office tape; three rolls with dispensers

    Candidate for paper joins and temporary attachment. Weigh installed tape and check retention on the actual assembly; this listing does not validate a structural joint.
    Prepare & check

    Tape the paper joints and attachments. Any later trim must be measured and positively retained; include tape and trim in assembled mass.

    Before building: Trim material, quantity and location require a balance study; no trim purchase is specified yet.

  • PLA fitting filament

    Enough for fittings, fit checks, supports and waste

    1.75 mm ordinary unfilled PLA; color is separate from material

    SUNLU Matte PLA Black SUNLU · specification reviewed 2026-09-28

    1.75 mm ordinary matte PLA; select Matte Black

    Candidate unfilled fitting filament. Record the actual spool and lot, inspect the slice, and verify each new part's dimensions and joint fit.
    Prepare & check

    Use the exact spool's profile and inspect the slice. A printed fitting still needs dimensional and joint checks with the selected stock.

Tools and equipment access

  • 3D printer access

    1 printer or access to one

    Bambu Lab P1S with 0.4 mm nozzle baseline, or a separately checked equivalent

    Bambu Lab P1S Bambu Lab · specification reviewed 2026-09-28

    P1S printer; 0.4 mm nozzle baseline, with plate and filament profile checked for each build

    Equipment reference, not a required purchase when printer access already exists. Slicer review and physical build evidence remain separate.
    Prepare & check

    Use the actual installed plate and nozzle. A P1S purchase is unnecessary if you already have compatible printer access; AMS is not required.

  • Caliper

    1

    Metric outside/inside diameter measurements

    PITTSBURGH digital caliper, 63731 Harbor Freight · specification reviewed 2026-09-28

    0–150 mm inside/outside caliper; 0.01 mm graduations; merchant-stated 0.03 mm accuracy

    Measure stock outside diameters and printed interfaces. Resolution is not proof of measurement accuracy; zero and check the instrument first.
    Prepare & check

    Measure supplied stock and printed interfaces; instrument resolution is not an accuracy guarantee.

  • Metric ruler

    1

    Millimeter markings for templates and assembly datums

    Westcott 10418 stainless-steel ruler Westcott / Acme United · specification reviewed 2026-09-28

    24 in stainless-steel ruler with inch and metric markings; single ruler

    Use the metric graduations for template scale and assembly datums. Confirm the selected product variant before purchase.
    Prepare & check

    Use the guide's named datum; a measurement from the nose cap is different from one from the straw end.

  • Small-parts scale

    1

    Resolution of 0.1 g or finer and capacity for the measurement setup

    American Weigh Scales AWS-600 pocket scale American Weigh Scales · specification reviewed 2026-09-28

    600 g capacity, 0.1 g readability

    Check calibration and setup; 0.1 g readability does not establish accuracy. This model uses a separate 500 g calibration weight, which is not included. Reuse a suitable scale if you already have one.
    American Weigh Scales 500 g calibration weight, 500WGT American Weigh Scales · specification reviewed 2026-09-28

    500 g; merchant-stated OIML class M2, ±0.075 g tolerance; certificate not supplied

    Optional tool accessory for the AWS-600 calibration procedure, not an aircraft part or ballast. Follow the exact scale's manual; other scales may require a different weight.
    Prepare & check

    Check scale accuracy with a suitable reference and include measurement uncertainty. Weigh the complete assembly, not only printed parts.

  • Scissors

    1

    Cut paper, straw or thread as required

    Fiskars Original scissors, 1069755 Staples · specification reviewed 2026-09-28

    8.41 in stainless-steel scissors; orange handle; one pair

    Paper and light consumable cutting only. Do not use these scissors for Scout carbon stock.
    Prepare & check

    Keep paper cuts clean and straw ends square without crushing the tube.

  • Paper printer or print-shop access

    1 template print at actual size

    A4 or US Letter printing on the selected paper weight

    A matching source has not been selected yet

    Prepare & check

    Use the supplied PDF, turn off fit-to-page, and check the scale bar. A print shop can provide this without purchasing a printer.

    Before building: Printing service depends on your location; no service is connected.

Prepare the paper wing

The paper is a shaped part of the design. Cutting, joining and folding happen after printing the template from your Studio package.

  1. Print one matching A4 or Letter template on 80 g/m² paper at 100% / actual size. Confirm the 50 mm scale bar before cutting.
  2. Cut both wing halves, tailplane and fin. Flip the right half so the tips point opposite ways and both leading edges face forward. Overlap the root strips by 5 mm: each cut root edge meets the other half's dotted boundary. Tape the overlap; do not crease the dotted lines. Target assembled span: 300 mm.
  3. Fold both leading strips 15° toward the underside along the dashed lines, equally on both sides. This is a forming target, not validated flight trim.
  4. Measure the straw, cut it to 210 mm, and dry-fit the fittings. Set the wing-saddle center 67.2 mm from the front end of the straw, excluding the nose cap. Center the wing span and half-chord over the saddle.
  5. Place the tail-bracket center 18 mm forward of the rear straw end. Attach the tailplane flat and the fin upright against its tab; keep it parallel to the straw and secure the fittings against rotation.
  6. Use START-HERE.html for the full assembly sequence. Record complete mass, balance, alignment and fit in Studio. This recipe has no established flight-test CG or trim procedure yet.

Read the preparation checks before ordering. These experimental designs still need physical assembly checks; any missing material choices are listed above.

Float · tethered balloon model

Starter baseline · experimental · check your saved design before purchasing.

Materials & sources10 requirements · current design

Gather the supplied components as well as the printed parts. Quantities below are for one build; store packs may contain much more. Reuse tools and printer access you already have.

Match the listed size and material before buying. Check current stock and delivery at the store; FlightHub does not show live prices or inventory. Linked parts still need fit checks in your build.

Components you supply

  • Balloon and helium

    1

    Party balloon; preview envelope is illustrative; size and available lift must be measured in Studio

    Balloon Time Jumbo Helium Tank Kit Balloon Time · specification reviewed 2026-09-28

    Helium/air tank kit with 50 nominal 9 in latex balloons and ribbon; mixture contains at least 80% helium

    Candidate Float gas and balloon source. Balloon size and available lift are not established by the recipe; measure lift with the intended airborne line. Keep the model tethered indoors.
    Prepare & check

    The kit includes balloons, gas and ribbon. Measure the actual additional lift with the intended airborne line; balloon size or a listing does not establish lift.

    Before building: Balloon size and required lift are not fixed by the recipe. Confirm sufficient measured lift in Studio before export.

  • Suspension line, tether and ground anchor

    Line for frame/tray plus tether; 1 ground anchor

    Indoor tether and stable anchor; exact hardware and line lengths not specified

    Gütermann Sew-All Thread Craft Warehouse · specification reviewed 2026-09-28

    100% polyester sewing thread; 109 yd spool

    Candidate suspension, tether or retention line. Length, knot retention and strength have not been tested for this assembly.
    Celebrate It fringe balloon weight Michaels · specification reviewed 2026-09-28

    5.25 oz / approximately 150 g balloon weight

    Ground anchor candidate only, never airborne ballast. Verify it holds the measured Float lift and that the tether attachment remains secure.
    Prepare & check

    Thread the printed eyelets, suspend the tray, and keep the model tethered indoors. The ground anchor stays on the table, not on the aircraft.

    Before building: Line lengths, joint retention and required anchor mass need a measured setup check. A 150 g candidate anchor is not a validated requirement.

  • Retained ballast

    Determined after lift and mass measurements

    Set only after measuring available lift and complete mass in Studio

    A matching source has not been selected yet

    Prepare & check

    Choose ballast only after measuring available lift and complete added mass; secure it in the tray against falling out.

    Before building: No reviewed ballast product or amount yet; tray fit and retention must be established.

Filament and consumables

  • Attachment tape

    As needed; weigh installed amount

    Lightweight attachment tape

    Scotch Magic Tape with dispensers, 3 rolls Staples · specification reviewed 2026-09-28

    3/4 in × 300 in matte-finish office tape; three rolls with dispensers

    Candidate for paper joins and temporary attachment. Weigh installed tape and check retention on the actual assembly; this listing does not validate a structural joint.
    Prepare & check

    Record installed tape in the added mass budget; do not double-count items already in the lift measurement.

  • PLA fitting filament

    Enough for fittings, fit checks, supports and waste

    1.75 mm ordinary unfilled PLA; color is separate from material

    SUNLU Matte PLA Black SUNLU · specification reviewed 2026-09-28

    1.75 mm ordinary matte PLA; select Matte Black

    Candidate unfilled fitting filament. Record the actual spool and lot, inspect the slice, and verify each new part's dimensions and joint fit.
    Prepare & check

    Use the exact spool's profile and inspect the slice. A printed fitting still needs dimensional and joint checks with the selected stock.

Tools and equipment access

  • 3D printer access

    1 printer or access to one

    Bambu Lab P1S with 0.4 mm nozzle baseline, or a separately checked equivalent

    Bambu Lab P1S Bambu Lab · specification reviewed 2026-09-28

    P1S printer; 0.4 mm nozzle baseline, with plate and filament profile checked for each build

    Equipment reference, not a required purchase when printer access already exists. Slicer review and physical build evidence remain separate.
    Prepare & check

    Use the actual installed plate and nozzle. A P1S purchase is unnecessary if you already have compatible printer access; AMS is not required.

  • Caliper

    1

    Metric outside/inside diameter measurements

    PITTSBURGH digital caliper, 63731 Harbor Freight · specification reviewed 2026-09-28

    0–150 mm inside/outside caliper; 0.01 mm graduations; merchant-stated 0.03 mm accuracy

    Measure stock outside diameters and printed interfaces. Resolution is not proof of measurement accuracy; zero and check the instrument first.
    Prepare & check

    Measure supplied stock and printed interfaces; instrument resolution is not an accuracy guarantee.

  • Metric ruler

    1

    Millimeter markings for templates and assembly datums

    Westcott 10418 stainless-steel ruler Westcott / Acme United · specification reviewed 2026-09-28

    24 in stainless-steel ruler with inch and metric markings; single ruler

    Use the metric graduations for template scale and assembly datums. Confirm the selected product variant before purchase.
    Prepare & check

    Use the guide's named datum; a measurement from the nose cap is different from one from the straw end.

  • Small-parts scale

    1

    Resolution of 0.1 g or finer and capacity for the measurement setup

    American Weigh Scales AWS-600 pocket scale American Weigh Scales · specification reviewed 2026-09-28

    600 g capacity, 0.1 g readability

    Check calibration and setup; 0.1 g readability does not establish accuracy. This model uses a separate 500 g calibration weight, which is not included. Reuse a suitable scale if you already have one.
    American Weigh Scales 500 g calibration weight, 500WGT American Weigh Scales · specification reviewed 2026-09-28

    500 g; merchant-stated OIML class M2, ±0.075 g tolerance; certificate not supplied

    Optional tool accessory for the AWS-600 calibration procedure, not an aircraft part or ballast. Follow the exact scale's manual; other scales may require a different weight.
    Prepare & check

    Check scale accuracy with a suitable reference and include measurement uncertainty. Weigh the complete assembly, not only printed parts.

  • Scissors

    1

    Cut paper, straw or thread as required

    Fiskars Original scissors, 1069755 Staples · specification reviewed 2026-09-28

    8.41 in stainless-steel scissors; orange handle; one pair

    Paper and light consumable cutting only. Do not use these scissors for Scout carbon stock.
    Prepare & check

    Keep paper cuts clean and straw ends square without crushing the tube.

Read the preparation checks before ordering. These experimental designs still need physical assembly checks; any missing material choices are listed above.

Scout · unpowered bench study

Starter baseline · experimental · check your saved design before purchasing.

Materials & sources13 requirements · current design

Gather the supplied components as well as the printed parts. Quantities below are for one build; store packs may contain much more. Reuse tools and printer access you already have.

Match the listed size and material before buying. Check current stock and delivery at the store; FlightHub does not show live prices or inventory. Linked parts still need fit checks in your build.

Components you supply

  • Carbon wing tubes

    2

    8 mm OD × 6 mm ID carbon tube; nominal cut length 490 mm each; coupon and actual stock check required

    Aloft carbon-fiber tube, 8 × 6 mm Aloft Hobbies · specification reviewed 2026-09-28

    8 mm outside diameter, 6 mm inside diameter, 1 m stock length

    Scout wing-spar stock candidate. Plan stock from the saved cut lengths: the extended span needs two 1 m tubes; compact and standard may share one if cutting allowance fits. Check tolerances, printed fit and joint strength.
    Prepare & check

    Mark each cut after dry assembly; allow for cutting loss. Compact (2 × 440 mm) and standard (2 × 490 mm) can use one 1 m tube only if the verified cuts and cutting loss fit. Extended (2 × 540 mm) requires two 1 m tubes. Legacy recipes use their listed cut lengths.

    Before building: Tube tolerances, printed sleeve fit and joint strength need coupon checks.

  • Carbon boom

    1

    6 mm OD carbon tube; 560 mm nominal; coupon and stock check required

    Aloft carbon-fiber tube, 6 × 5 mm Aloft Hobbies · specification reviewed 2026-09-28

    6 mm outside diameter, 5 mm inside diameter, 1 m stock length

    Scout boom diameter candidate. The recipe fixes outside diameter but not wall thickness; stiffness, printed fit and strength remain unverified.
    Prepare & check

    One 1 m stock length can supply the nominal 560 mm boom. Check actual stock, fit and stiffness before cutting.

    Before building: The recipe specifies outside diameter but not wall thickness. The linked 6 × 5 mm tube is a candidate, not an approved structural selection.

  • Horizontal-tail carbon rod

    1

    3 mm OD carbon rod; 380 mm nominal; coupon and stock check required

    Aloft solid carbon-fiber rod, 3 mm Aloft Hobbies · specification reviewed 2026-09-28

    3 mm solid carbon-fiber rod, 1 m stock length

    One stock rod can supply the nominal Scout 380 mm tail and 160 mm fin cuts with cutting allowance. Check actual diameter, fit and joint strength.
    Prepare & check

    A single 1 m rod can supply this 380 mm piece and the separate 160 mm fin piece, allowing cutting loss.

    Before building: Check actual diameter, printed fit and joint strength.

  • Fin carbon rod

    1

    3 mm OD carbon rod; 160 mm nominal; coupon and stock check required

    Aloft solid carbon-fiber rod, 3 mm Aloft Hobbies · specification reviewed 2026-09-28

    3 mm solid carbon-fiber rod, 1 m stock length

    One stock rod can supply the nominal Scout 380 mm tail and 160 mm fin cuts with cutting allowance. Check actual diameter, fit and joint strength.
    Prepare & check

    Cut from the same 1 m stock as the tail rod after dry fitting; do not buy a second rod just for this row.

    Before building: Check actual diameter, printed fit and joint strength.

Filament and consumables

  • Adhesive for carbon and printed parts

    Amount established by joint trials

    Compatible adhesive selected and tested in Studio

    A matching source has not been selected yet

    Prepare & check

    Test adhesion on the actual carbon, PLA and LW-PLA coupons before bonding the assembly.

    Before building: No adhesive and bond process have been qualified. A generic glue link would imply compatibility we have not established.

  • Joint and ballast retention

    Tape/thread as needed; ballast not specified

    Temporary seam tape, retention thread and any later measured ballast

    Scotch Magic Tape with dispensers, 3 rolls Staples · specification reviewed 2026-09-28

    3/4 in × 300 in matte-finish office tape; three rolls with dispensers

    Candidate for paper joins and temporary attachment. Weigh installed tape and check retention on the actual assembly; this listing does not validate a structural joint.
    Gütermann Sew-All Thread Craft Warehouse · specification reviewed 2026-09-28

    100% polyester sewing thread; 109 yd spool

    Candidate suspension, tether or retention line. Length, knot retention and strength have not been tested for this assembly.
    Prepare & check

    Tape alone is not a validated flight joint. Secure ballast through the carrier; select its mass only after the balance study.

    Before building: Final retention system and ballast remain unestablished.

  • LW-PLA shell filament

    Enough for shells, calibration, supports and waste

    1.75 mm active-foaming LW-PLA

    colorFabb LW-PLA Black colorFabb · specification reviewed 2026-09-28

    1.75 mm active-foaming lightweight PLA; select the 1.75 mm variant

    Scout shell material candidate. Calibrate the exact spool's foaming, flow and print process; ordinary PLA is not an equivalent shell material.
    Prepare & check

    Select 1.75 mm stock and calibrate the exact manufacturer's temperature/flow process. Standard PLA is not a substitute for the shell material.

    Before building: No calibrated profile or effective density is established for this design.

  • PLA fitting filament

    Enough for fittings, fit checks, supports and waste

    1.75 mm ordinary unfilled PLA; color is separate from material

    SUNLU Matte PLA Black SUNLU · specification reviewed 2026-09-28

    1.75 mm ordinary matte PLA; select Matte Black

    Candidate unfilled fitting filament. Record the actual spool and lot, inspect the slice, and verify each new part's dimensions and joint fit.
    Prepare & check

    Use the exact spool's profile and inspect the slice. A printed fitting still needs dimensional and joint checks with the selected stock.

Tools and equipment access

  • 3D printer access

    1 printer or access to one

    Bambu Lab P1S with 0.4 mm nozzle baseline, or a separately checked equivalent

    Bambu Lab P1S Bambu Lab · specification reviewed 2026-09-28

    P1S printer; 0.4 mm nozzle baseline, with plate and filament profile checked for each build

    Equipment reference, not a required purchase when printer access already exists. Slicer review and physical build evidence remain separate.
    Prepare & check

    Use the actual installed plate and nozzle. A P1S purchase is unnecessary if you already have compatible printer access; AMS is not required.

  • Caliper

    1

    Metric outside/inside diameter measurements

    PITTSBURGH digital caliper, 63731 Harbor Freight · specification reviewed 2026-09-28

    0–150 mm inside/outside caliper; 0.01 mm graduations; merchant-stated 0.03 mm accuracy

    Measure stock outside diameters and printed interfaces. Resolution is not proof of measurement accuracy; zero and check the instrument first.
    Prepare & check

    Measure supplied stock and printed interfaces; instrument resolution is not an accuracy guarantee.

  • Metric ruler

    1

    Millimeter markings for templates and assembly datums

    Westcott 10418 stainless-steel ruler Westcott / Acme United · specification reviewed 2026-09-28

    24 in stainless-steel ruler with inch and metric markings; single ruler

    Use the metric graduations for template scale and assembly datums. Confirm the selected product variant before purchase.
    Prepare & check

    Use the guide's named datum; a measurement from the nose cap is different from one from the straw end.

  • Small-parts scale

    1

    Resolution of 0.1 g or finer and capacity for the measurement setup

    American Weigh Scales AWS-600 pocket scale American Weigh Scales · specification reviewed 2026-09-28

    600 g capacity, 0.1 g readability

    Check calibration and setup; 0.1 g readability does not establish accuracy. This model uses a separate 500 g calibration weight, which is not included. Reuse a suitable scale if you already have one.
    American Weigh Scales 500 g calibration weight, 500WGT American Weigh Scales · specification reviewed 2026-09-28

    500 g; merchant-stated OIML class M2, ±0.075 g tolerance; certificate not supplied

    Optional tool accessory for the AWS-600 calibration procedure, not an aircraft part or ballast. Follow the exact scale's manual; other scales may require a different weight.
    Prepare & check

    Check scale accuracy with a suitable reference and include measurement uncertainty. Weigh the complete assembly, not only printed parts.

  • Carbon cutting and dust protection

    Suitable cutting setup and protection

    Tools and protective equipment appropriate to the carbon supplier's cutting instructions

    A matching source has not been selected yet

    Prepare & check

    Use the supplier's cutting and dust-control instructions; do not use paper scissors for carbon stock.

    Before building: A complete cutting/tool procedure has not been selected for this kit.

Read the preparation checks before ordering. These experimental designs still need physical assembly checks; any missing material choices are listed above.