Build, Use, Damage, Mend and Adapt – an approach to learning through and about drones


A guest post by Ed Charlwood

What follows describes the work I’ve been doing in school that has led to me to set up a new Drones in Schools Google+ community for teachers.

A convergence of influences

As with much curriculum development, serendipity did its job at the outset of this endeavour, bringing together the opportunities offered by (1) the new GCSE and A Level specifications and their broader content requirements, (2) a growing dissatisfaction with a certain high-profile external “design / engineering” competition that really requires very little design and (3) the discovery of a very interesting little kit. Firstly, the long-awaited publication of the new GCSE and A Level specifications really was a wake up call that we could not continue to plough the same RM / Product Design furrow at either qualification level. I felt it important to embrace the specification in its entirety and that meant that at Latymer we would have to teach areas that were less familiar i.e. Systems and Control and Textiles. It also meant that we could fully embrace previously fringe areas that we had been pushing at for a few years but had been confined by old assessment criteria, namely the use of CAD, CAM and the circular economy. Secondly, I have seen our students be equally engaged and frustrated with external engineering competitions, they promised a glimpse into the competitive world of high level engineering but actually offered little real decision making, restrictive and difficult manufacturing processes and actually required a lot of luck and frivolous administration. I won’t name names. Lastly I came across a $99 / £78 kit from Flexbot, offering a 3D printable drone and the promise of an open source kit. A quick PayPal purchase later and I was the proud owner of a Flexbot Quadcopter (4 rotors), cleverly packaged, with a comprehensive and appropriate information booklet and a product that worked pretty much straight out for the box and could fly via an iPhone app. Bingo.

Drones are a great ‘hook’ for learning

Drones are popular in the media, comprehensible to most people and on a steep curve of becoming demonstrably better and cheaper at the same time. Currently they have the elusive “engagement factor” and this provides a ‘hook’ making them intrinsically attractive to students. Such a hook is, in my experience, vital. It is important to note that we are not coding experts, nor are we overly interested in programming. But we are interested in using electronics to do stuff. And it is here that the Flexbot Quadcopter meets our teaching intentions.

Our approach

Under the guidance of my colleague Nick Creak we handed the kit over to our students. They assembled the drone without difficulty. Then they had a play, crashed it and naturally broke it. They took the kit apart and made some key measurements, download CAD files from the Flexbot Wiki (SketchUp) and Thingiverse (.stl) and printed a replacement for the part for the one they broke. They then began to explore the files and started to design their own drone. Initially they did this by pretty much by simplifying and copying the existing design, a useful process in its own right to develop CAD techniques and collaborative skills.

A 3D printed Flexbot part

We then printed their chassis designs and used the slicing software to investigate various manufacturing options:

  • How long would the print take if it was “ultimate” or “low” quality?
  • What would happen if it had a low / medium / dense fill?
  • What were the implications of the design being aligned differently?

On average a “normal quality” high density print would take 2 hours. The booklet provided by Flexbot also has some interesting text comparing the economics of 3D printed manufacturing vs mass production techniques like injection moulding.

Students then could begin to design “iteratively” – a new key concept in the OCR interpretation of the new specifications.

“Iterative design is a design methodology based on a cyclic process of prototyping, testing, analysing, and refining a product or process. Based on the results of testing the most recent iteration of a design, changes and refinements are made.”

We also offered a number of design challenges: design a modular drone, alter your design to use as little filament as possible (make it cheap!) or to print as quickly as possible, design your drone to use a standard component – in our case this was a Lego axle.

Flexbot parts

The Flexbot circuit is robust enough to be shared between students and the batteries, propellers and motors are cheap enough to buy in bulk. If you do not have a 3D printer, jobs can be specified, costed and outsourced to a 3D print hub. The simulator (which is available once you have started the process of uploading parts for hub to print) shows it would cost approximately £6 for a basic chassis made from PLA by Fused Deposition Modelling. Some hubs even offer 25% student discount and most do almost next day delivery.

We additionally posed a number of extensions questions to our students, each eliciting a different design outcome: What is the effect of changing the alignment of the rotors? How big/small can the drone be? How much weight can it pick up?

Reflections

Design Decisions Pentagon

David Barlex has produced a design decision pentagon to describe the decisions that students might make when they are designing and making. So I was intrigued to use this to explore the decisions that our students were making.

Clearly they weren’t making any big conceptual decisions – the sort of product had already been decided – a quadcopter drone. The technical decisions in terms of how it would work had also been decided – four electric motors linked to flexbot circuit, controlled by the Bingo app. But there were lots of possibilities in the constructional decision-making.

Not 90°!

One student changed the alignment of the motors so that they were no longer at 90o to one another which made the drone faster but harder to control. And I suppose you could argue that this constructional change did in fact change the way the drone worked. A key feature of the pentagon is that the design decisions featured at each of the vertices aren’t independent of one another hence the lines between the vertices.

Interference fit

Another student responded to the modular challenge producing a design with four separate arms held tightly by an interference fit to the central node, taking advantage of the high degree of dimensional accuracy of additive manufacture. This required investigation and was in itself was a valuable learning experience.

Clearly it’s possible to set particular design challenges around constructional decisions e.g. making it more crash worthy.

Aesthetic decisions could also be made. Indeed changing the alignment of the motors could be seen as an aesthetic as well as a constructional decision. Devising light-weight covers that can be 3D printed or perhaps produced from nets that have been laser cut from thin sheet plastic might give the drone different ‘personalities’ and this may be seen as a marketing decision, changing the appearance to have appeal to different users. Marketing decisions can also be made with regard to how the drone gets to market – via a kit in a shop or on line, or via digital files for home or hub manufacture in collaboration with a circuit board/electrical motor supplier, related to this, deciding whether the product is open source or not is also a marketing decision. And just who the drone is for will make a big difference to what it might look like and additional features. And taking a step back how will the design decisions overall be affected by requiring drones to be part of a circular economy?

There is, of course, a “purer” engineering challenge, to design and make racing drones, where there are already a number of competitions with related rules and constraints.

The next area for us to consider is that of the consequences of drone technology, and its close cousin the Unmanned Aerial Vehicle (UAV) many of which have some more sinister applications; bombing, surveillance and smuggling as a counterbalance to the positive aspects; photography, delivery, surveying etc… each is a rich seam for discussion as well as the wider issues of automation, disruptive technologies generally or government regulation and control.

Far from this being a proprietary endeavour I want this to be a collaborative, open source one, so I invite you to join the Drones in Schools Google+ community to share your experiences, ideas and resources or add your comments to this post.

Ed Charlwood headshotEd Charlwood

Head of Design & Director of Digital Learning at Latymer Upper School, London

I am a passionate advocate of Design education who believes in the power of learning through analysis, designing and making. I am an Apple Distinguished Educator (class of 2013), a Google Certified Teacher (class of 2015) and the DATA Outstanding Newcomer to Design and Technology Award winner (2008), a particular focus of my work is to exemplify the notion that innovative and appropriate use of technology can redefine the traditional teacher-learner relationship and transform educational designing and making experiences. My vision is to inspire and empower students to make the things they imagine.

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