How its Made- Mosquito Helicopter Rotor Blades - Factory Tour

in Trenton FL where this awesome Aircraft is built!
Link to the Mosquito Helicopter: composite-fx.com/
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[@bryancobb]

Dwight needs to teach Robinson Helicopters how to make blades that won't come apart in-flight.

[@retiredtom1654]

The quality to detail is very impressive. I never got a chopper license but have flown many hours. I often wondered about the construction of the blades. I'm still amazed at their strength.

[@bobsemp]

And that, my friends, is why the helicopter blades cost so much. Very impressive video. Thank you for sharing such detail with us!

[@ExperimentalAircraftChannel]

Hey! Thank you for taking the time to watch! We love learning right along with you.

[@robertcarveth8722]

I'm gobsmacked at the high level of accuracy and the technology used.

[@josephpriolo1514]

Very Nice, glad to see the high level of manufacturing

[@Robert-mn8gc]

The Little Mosquito Helicopter is just Sensational. Especially with the Turbine Engine

[@bobstovall9570]

This is, by FAR, the most interesting video I've seen on this channel. I have been fascinated by helicopters since I was a small child watching a TV show called 'Whirlybirds' which featured Bell helicopters, this was back in the '50's. It is just fascinating to me that this ultra-high aspect ratio 'wing' can support the weight of an aircraft and its passengers and cargo while, simultaneously, propelling it forward. Though I'm not rated for rotor wing aircraft I did get the chance to fly a Huey when I was in Vietnam and a friend of mine put me into the right seat and we sent for a tour of DaNang from Red Beach down to China Beach and then back again. You might say it was "The High Point" of my time in Vietnam, in every sense of the word. I love your channel and the work you do to promote experimental and innovative aircraft. Perhaps I will see you at Oshkosh in the future.

[@experimental_av]

This is amazing. My favorite type of video. Impressive the length they go into to ensuring constant quality with their blades. I've seen the "inner tube oven" process before when making carbon fibre bike frames. Never seen on aluminum.

[@victoryfirst2878]

I tip my hat off to you Sir for a first class act of manufacturing helicopter blades. All steps were covered with accurate information of process at hand. Good luck with your endeavors and keep on making the MOSQUITO HELICOPTER.

[@1951Roy]

Enjoyed watching the making of a rotor blade. Thanks

[@jasongrinnell1986]

That was pretty dang cool. Sure hope I get to visit that place one day. You know. When I pick up my mosquito.

[@catchulater7483]

Always like hearing about the boys in Trenton which is next door to my town of Williston. Ima get one of those lil helos!

[@Project2Aero]

Very interesting process. Gotta love that they just came up with machines to do what they needed!

[@noe616]

Most companies have to order custom made tools. You can't get around it.

[@gregadkisson4115]

The Junkin team brains at work! Make no mistake when seeing Dwight pounding nails or cleaning up the yard...It is his quality time to refresh his mind for the next project.

[@CraigVanSickleAK]

This is excellent. Love seeing the manufacturing detail.

[@PghGameFix]

You should do a follow up vid with the finishing of the blades. Balance, CG, and tracking after install.

[@QXZ9027MKII]

Much obliged sir for the tour, very insightful & scintillating, God bless them all.

[@mrreddog]

Very well thought out out manufacturing process, impressive.

[@Mrsournotes]

Very interesting to watch this process Bryan. Appreciate you posting this video.👍🏽👍🏽

[@keithfork8663]

Gotta love that custom roller.

[@0512d1d]

It's fascinating to see this. I learn a lot from this. I love aerospace engineering. I have 2 slides of a glider wing about 6 inches wide at home. The airfoil is made of fiberglass and epoxy and is made in the same way as the rotor blades, but the only difference is the type of material. I have also seen (honeycomb) rotor blades, I wondered why this type of sandwich construction is no longer needed

[@manojroy7741]

Your job is very good, and hard I like your job

[@johnmilner0859]

Fascinating 👏🏻👏🏻

[@kevspss]

Kinda like a fancy version of a gutter and siding maker.

[@Petermomo5050]

InterestingIt appears these guys care for the safety of the pilot's safety.

[@amtechnician6098]

Good job 👍 this is what have been searching

[@abundantharmony]

Sure wish you didn't add that brostep background music.

[@myotherusername9224]

+1 video producers need to use tripods, lose the irritating music and lose 'transitions' between scenes, a simple cut is all we need.

[@abundantharmony]

@@myotherusername9224 I'm down for transitions if they're proper and simple.

[@andybryson3887]

Awesome video. so much high tech even in a small 1 man helicopter. I luv it!

[@ptonpc]

Very interesting video. Thanks :)

[@iforce2d]

Thanks, I enjoyed this :)

[@raydreamer7566]

When they did the pull apart test I was kind of hoping that there would have been a readout of how much force was used to pull the glued parts until separation occurred. I am guessing that maybe that is not important because the cut test coupons were not cut to to a pattern size so there would always be a difference. I am thinking there is an expectable range of pull force separation needed and it sounded like the glue tape showing that it was bonded to each side of the glue joint was more important then the actual force to separate the two glued surfaces. Great learning video. With this kind of manufacturing ability I am wondering if these blades would be for sale so builders can use them on other projects if the projects were approved by the Mosquito Helicopter company ?

[@lj6278]

There is defiantly a calibrated gauge reading pull strength, and the coupon has to fall within an expected range. There is a lot of liability (possible lawsuits) riding on these parts. Some things weren't shown for proprietary reasons I'm sure.

[@raydreamer7566]

Yes I saw the gage and was hoping that they would share the expected reading per linear inch of glued area. But it’s ok. I really enjoyed the build process of the blades.

[@adredy]

For me epoxy glue and nothing else :/ quite scary in helicopter blades , i used a lot epoxy with aluminium and for me this not work good , plus working temperature .... this must be strong glue on the sun those blades can reach really high temp , but what i know :)

[@lj6278]

​@@adredy Hi, Epoxy, in this case, is misleading. As you saw in the video, it is in tape form. There are mainly two types of adhesive tape supported and unsupported. this was supported tape. Picture the cloth-like material in duct tape sandwiched between adhesive layers. the cloth helps in many ways. The heat-up, dwell, and cool-down are critical. Plus, the pressure of the mold surfaces is just enough to not cause the adhesive to squeeze out. In my industry, we use vacuum bagging and a mold or bond jig To keep the desired pressure. All of this goes in an autoclave the size of a 747 fuselage at 75 PSI and 350F for 8Hrs. So the bond between the two aluminum skins is stronger and more reliable than regular epoxy. During service, the Blades don't encounter heat anywhere close to 350F, so the epoxy stays stable during the blade's service life.

[@kentcostello5286]

OMG. That looks like a awesome setup .

[@mahyadnaadlaw3112]

W/ this kind of manufacturing process it's as good as certified.

[@stealhty1]

Thanks for share very informative

[@nebojsanesic5326]

I love how they used roller blade wheels for the rollers of the metal sheet forming machine they made.

[@CanadianGrenadian]

Fabulous fabulous fabulous

[@donjohnson2639]

Wow that’s some process 👍

[@noe616]

This was amazing.

[@WireWeHere]

A PID controller, a few thermocouples and a proportional gas valve make a great start for oil right consistent temperature regulation of a gas fired deep fryer of turkeys, chickens, wings, sweet potatoes and spuds plus a few others I'm no longer hungry enough to recall. PID is Proportional, Integral and Derivative are mathematical relationships between the current and target temperature that work as a team to calculate the percentage of total heat available to apply in order to maintain the current ramping target and the soak temperature. The PID controller can with the right features take care of ramp up, soak and cool down timing. They work well with Proportional Solid State Relays, SSR, for a variable electrical output.. but worth noting is the common failure mode of an SSR is in a closed/full on output state, they rarely fail in an open/off state. Once I get started it's good to clear some memory from storage. Thanks for sharing of the forming and bonding technique. Does this company use 3M literature's 30% sulphuric acid to water mixed with red stuff (slipped my mind) etching solution to prep for bonding or something trade secretly else? Always curious.

[@Gram-Banglar83]

I want to learn to work. Can you please give me a chance to learn?

[@nightshift5201]

They're very careful not to show top secret stuff. Good for them. Very high quality production.

[@sourshoes1465]

I don’t know….. I thought this(rotor blade mfg) was pretty much the last of their secrets? I’m honestly kinda shocked that they allowed this video to made. So glad they did though.

[@rotarywingusa4519]

Great video's. Gyro Technic would be a great manufacturer to do a factory tour of.

[@william1863]

Cool 👍

[@MsRandiCook]

W O W!

[@2779mattie]

Very interesting

[@kizzjd9578]

Are they not foam filled?

[@dschlott16]

I have some TH-55/Hughes 269 rotor blades that I have cut up. They have a remarkably similar cross section - extruded aluminum nose bonded to aluminum sheet, brass leading edge, weight on blade tip, reinforced blade root section etc. I'd be happy to send you some cuts or some images so your engineers and technicians have more reference material.

[@pilotmiami1]

Bravo.go ahead

[@carolinabearhawk8132]

Really cool!!

[@Kicker700]

Where can I buy that epoxy tape from?

[@francisconti9085]

Nice!!

[@oby-1607]

We have a table that has one inch steel plates top and bottom with a steel honeycomb sandwiched between the plates. Once they are all joined the top plate is ground flat. All this ensures the surface remains flat in cooling and heat cycles.

[@sarcamahardika]

Nice❤

[@kiransadventures]

Why don't you weld the trailing edge?

[@dudleysmith5111]

It appears the blades do not have any twist. Is that correct?

[@robertlafnear7034]

When all is said and done I am wondering why they have not transitioned from Aluminum to Carbon Fiber for the blades🤔.... a different process but a stronger/lighter blade I'd bet . Nice shop and thanks for the tour to them and you too.😆

[@phatboizbackyardkustomz9006]

Talking to Dwight in the past, I think it is a cost thing. The carbon blades are more expensive.

[@robertlafnear7034]

Yeh,.. sometimes people try and cut corners... I would prefer an upgrade Carbon Fiber blade over a glued aluminum 'cause it's my butt hanging on that blade.,..AND looking at the ends I saw a GAP I didn't like at all and the pull apart test did not impress me.......... but that's just ... ME. Thanks 😁

[@chippyjohn1]

The forces and speed these little toy helicopters go through don't mandate a composite rotor. Composite is also heavier. These helicopters dont travel much over 100km/h they dont really carry any weight and they are a two blade rotor.

[@robertlafnear7034]

Carbon Fiber is 50% lighter than Aluminum... The engines have limited H.P. ,... less energy to drive the blade.. more to power the vehicle.... look at the Big Turbine builders, the fan blades are Composite /Titaniam not Aluminum for a reason.🤔

[@chippyjohn1]

@@robertlafnear7034 You didn't read what I wrote, and you obviously don't understand how or what a composite blade is made from. We are talking about helicopter rotors here, no fan blades, very different design.

[@jmikronis7376]

Ahhhhhhh. Nicely done. No aluminum rods or stainless rods as in the first video I watched. This one is done right. Epoxy filled. My bad. The first video was from ultralight helicopter, not your channel.

[@bachoqobalia5694]

Hello. Size and what are the blades on the gyroplane

[@shivukannadaboy]

❤im village boy from india i love mosquito helicopter.Mosquito helicopter price bro... 😍😍

[@NotSure416]

Why is there such a sharp crease on the reflex?

[@smokken10]

HMS? No fiber dress and oil in the bonding area?

[@baktimuni8315]

How long Length and Dia the Blade bro

[@parulparul6436]

what is ratio of lenth and width gyirocopter rotor blade

[@irfanbaig6077]

Aluminium sheet size? And length of blades? Please replay to me

[@jamaicataekwondofederation5013]

I notice that it did not have any twist so that it is not as aerodynamically efficient

[@TrevorDennis100]

I do hope Mike Patey got to see this video. It's not like he has any spare time to browse KZbin, so it is unlikely unless someone points it out to him.

[@HADDEN67]

Did you try making any Carbon Fibre Prepreg blades in the mould ?

[@deezynar]

No twist in the blades?

[@crawford323]

How was the choice of the airfoil made and how does the airfoils differ from that of a Gyroplane. Why do gyroplanes not use your choice of airfoils if both aircraft will find it necessary to Autorotate? Does this airfoil have a limited area of pressure travel? What is the relationship between the mass and the aerodynamic center. How much twist do the rotor have during use? Does the rotor cone when loaded or is the coming angle set by the rotor head? Inquiring minds want to know.

[@Jkauppa]

try dried biomass flour putty carbonization in oven directly as carbon ceramics sintering process, ie cast carbon fiber

[@Tommy-pg1ci]

Looks like the 1967 Scheutzow Bee design.

[@lj6278]

Is the etching of the aluminum done with Alodine? If so, it should not be wiped on. It should be dabbed on and added off with DM water. wiping breaks down the peaks and fills the valleys of the etch. a cross-view of the surface at magnification can show an obvious difference. I am sure you know this. It looks like you have done your research. Is the cavity from doubler to end weight empty, besides the leading edge spar? Having better cleanroom standards will help in any future quality control issues and possible litigation. Good luck and much success.👍

[@olivertaylor8788]

Now I know where all the liquid nail adhesive goes.

[@earlsammesios8696]

Sir ,how meny inchis long the,and how meny wide the blade sir

[@JeffChoppah]

How do they go about blade twist? For lift distribution at tip and root? Or the aerofoil thickness bigger at root than at tip,? Because I don't seem to see that difference, or lift distribution isn't that critical on this?

[@brianb-p6586]

There is no static twist. The extrusion isn't twisted as it is manufactured, and while the CNC could form the twist, there would need to be much more excess material; the alternative (which is actually used by major manufacturers) is to heat and twist the extrusion after machining. Also the dies and moulds for every other step would also need the twist; that's viable for major manufacturers, but not for this operation. Aerodynamic forces probably twist the blade somewhat during operation but fundamentally it just doesn't have the twist that an optimal rotor blade would have.

[@JeffChoppah]

@@brianb-p6586 I read twist-less blades are less effective or what are the major drawbacks to having a blade with no twist. I also built mine in this manner (check video) and no twist, yet to test it and see the effects, but if I was to built them again I would machine thinner profile thickness towards tip instead of twist.

[@brianb-p6586]

@JeffChoppah they are less effective (less lift) and less efficient (more power to get the required lift), but I don't know by how much.

[@amauriernanibaleki5578]

Hy!!! You export only blades from Brasil. How price?

[@1tobicat]

I wondered where all the roller blade wheels went.

[@DanFrederiksen]

Elaborate. Isn't carbon fiber ultimately simpler?

[@dens_pasundan]

mantap

[@deltamangr6247]

Thought these were baked composites!

[@Raul28153]

At 19:56 I saw that the spar was not well seated in the skin leaving a substantial air gap.

[@homeworld1031tx]

This looks like the end of the blade where the resin has squeezed out and would obscure visibility of any gap

[@Raul28153]

@@homeworld1031tx I can see it. Thing is, there was nothing forcing the spar into the blade skin and when they cooked it it didn't even have gravity working for it.

[@homeworld1031tx]

@@Raul28153 The video spent minutes explaining that multiple silicone bladders are used to inflate inside of the part cavity to press the spar into the wing skin.

[@Raul28153]

@@homeworld1031tx must have missed that part. But they didn't leave them in, which is interesting because the might have been able to depending o the material and the heat involved. Thing is I see a gap. Now to be honest I don't know the significance of a gap from an engineering perspective. It may be moot, or not.

[@waderoberson1864]

​​​@@Raul28153 Hi, I'm the blade builder at compositefx and one of the people shown in this video. While the air gap you're pointing out does exist, it does not extend past the test sample shown being cut away from the blade. The silicone tubes that inflate and push the spar into the leading edge were used. The part where we removed them was cut from the video (I assume for the sake of keeping the video from getting too long-winded). Hope this helps.

[@pilotcatze-0158]

I love you

[@metalillness5951]

I'm wondering what "aircraft grade aluminum" actually is in his mind? Been a tool maker for a very long time and it reminds me of "rich Corinthian leather" type terminology.

[@Sergeant898]

"aircraft grade" is BS terminology. It's probably a 2XXX or 3XXX grade, maybe 2024 since they are bending and forming it.

[@dodafarias9753]

A dorei cara quero ver mais

[@ThomasSchick]

👍🏻

[@NanaSumarna-dj8rh]

Kalau beli baling baling nya berapa ?

[@sheepdog1102]

Fairly complicated 😊 to say the least.

[@robertschulke1596]

I’m rather surprised that the airfoil cross section is constant while the airspeed varies significantly with the distance from the rotor hub.

[@myotherusername9224]

I ask that same question whenever I can. Look at how the airfoil changes from root to tip on a hi performance sailplane or a wind turbine - highly optimized. Why not here ? Scratching my head...

[@rolnthunder6737]

Cost, weight and simplicity. Keep in mind guys this is a 50k ultralight/experimental.

[@robertschulke1596]

@@rolnthunder6737 i get it, but the bespoke heated molds could as easily cure pre-preg, and a CNC mill can make them any shape desired. Alternatively, room temperature curing resins let you make simple fiberglass molds off of a carved wood original. Then again, working with a new, complex technology increases costs and imposes a learning curve.

[@Iboxx]

Wouldn’t hydroforming be much faster and cheaper?

[@NanaSumarna-dj8rh]

Boleh minta 2 bilah nya

[@patrickvanbiljon3332]

Not a full composite blade and small compaired to a full composite blade made for a MI 24 These blades outlive the aircraft structure easily

[@ExperimentalAircraftChannel]

com.pos.ite - made up of various parts or elements. That is all. :-) Thank YOU for taking the time to watch. We appreciate YOU!

[@brianb-p6586]

@@ExperimentalAircraftChannel Literally, yes, but in the context of aircraft construction that's not what "composite" means. The blade is a fabricated assembly, not a "composite". A composite in this context is a material with more than one component, such as fibre-reinforced polymer.

[@dnXprq9]

Please standardized the safety first for the workers use properly PPE🙏

[@huey-fan8335]

Higher quality than Boeing

[@FrancisTucker-k5m]

Hi flying humans, am Francis tucker a Sierra Leonean living in the capital city Freetown in the west coast of Africa. Am also an African fing much interest in this tech and currently am building a single seater from scratch using local materials. However am in need of two navigation instruments such as the tachometer and the altimeter and am pleased to ask if you could assist me earn them. Pls. Respond when convenient. Await to hear from you. Tks.

[@richardwallinger1683]

wow 30 years of supplying R/C model helicopters and giving hands on tuition to thousands of customers .one or two potentially lethal experiences . never trust a customer .Double / treble check everything .. missing one thing will almost certainly be deadly ..

[@stuarttayler8681]

Aluminum is so old tech why would you spend so much on forming and bonding when composites would give you a simpler process with double the life on the blades.

[@RamadhanySyahputra]

Berbahasa Indonesia bisa

[@henrychan720]

Why can't it just be an extrusion?

[@brianb-p6586]

That would be a large and very thin-walled extrusion... but it might be possible.

[@kelleysimonds5945]

Could have been fun to watch without that distracting music, couldn't finish watching it.

[@downtoearthconstruction]

Like a glorified Pittsburgh machine