Upgrading a Solar-Powered RC Plane with SOLIDWORKS for Makers – Part 2

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What would you do if your solar-powered, remote-controlled (RC) plane lost power mid-flight and came crashing down? For James Whomsley from Project Air, the answer was simple: figure out what went wrong with that plane, the Solar 2, rebuild, and try again.

The Solar 3 is James’s latest iteration of an ambitious project to achieve sustainable solar flight by creating an RC plane that harnesses renewable energy. The plane generates more power than it consumes to stay airborne using only solar energy.

Note: if you missed Upgrading a Solar-Powered RC Plane with SOLIDWORKS for Makers – Part One, you can read it here. 

Learn more about SOLIDWORKS for Makers for personal projects – just $48/USD, per year.

James needed to design an efficient power system with optimized solar panels, build a sturdy aircraft, and troubleshoot problems—both expected and unexpected—all while applying aerospace principles to keep things lightweight and aerodynamic. Solar 2’s initial crash revealed an issue with the power system, so the team set out to redesign the electronics, test their ideas, and build a stronger, smarter plane.

A Smarter Power System

The first step was investigating what caused the failure. It was a feature they didn’t even know existed—a built-in battery disconnect that kicked in during low sun conditions, limiting the efficiency of the solar cells. Working with Matt from DIY Perks, the team simplified the power system using a voltage regulator, bypassing the need for a charge controller. The new system was tested and passed with flying colors before being installed in the rebuilt plane.

Rebuilding the Solar 3

After Solar 2’s crash, James also needed to rework the plane’s design. Using xDesign, part of the SOLIDWORKS for Makers package, they quickly adjusted key components like the motor mount and propeller assembly, ensuring it was stronger for the next flight. The browser-based tools made it easy to iterate, even on a Mac, and the design was soon ready to take to the skies.

Flight Testing and Lessons Learned

The first test flight of the Solar 3 showed promising signs, with the upgraded power system successfully sustaining the plane in the air. However, as soon as it encountered turbulence, new challenges became apparent. The reinforced wings, now fitted with aluminum brackets for added strength, were heavier, making the plane less nimble. This weight and its large wingspan made it harder to control the plane in strong wind.

At 75 percent throttle, the plane could hold altitude, resembling a glider in its ability to stay aloft, but each gust sent the wings flexing and wobbling. The autopilot worked overtime to stabilize the flight, but every adjustment underscored a critical flaw in the design: the wings were too flexible to handle real-world conditions consistently. Even worse, the extra weight and drag made climbing a struggle at full throttle.

Eventually, the plane needed an emergency landing after a tense few minutes in the air. Despite a careful descent, the heavy structure led to more damage upon touchdown. Post-flight analysis revealed the electric motor mount had snapped, and the wings needed further stiffening. While it wasn’t the test flight James hoped for, they gained crucial insight into how much power was required to stay airborne and the limitations of the current airframe design.

The team quickly realized they’d need a lighter, more efficient solar-powered aircraft design to handle wind and reduce power consumption for future iterations. These lessons would set the stage for the next phase of their solar plane program.

Refining the Design with SOLIDWORKS for Makers

James relied on SOLIDWORKS for Makers to make critical adjustments to their solar-powered RC plane, like reinforcing the motor mount and testing different design approaches.

 

SOLIDWORKS for Makers includes two packages: browser-based apps that work on Mac and Chromebook and 3DEXPERIENCE SOLIDWORKS for Makers for Windows. Either package provides the flexibility to design wherever you are.

With SOLIDWORKS for Makers, you can access powerful tools to bring your ideas to life. You’ll get everything you need to tackle ambitious projects, from using xShape for intuitive Sub-D modeling to craft smooth, organic forms to refining precise design details in xDesign. Plus, it’s just $48 a year (or $15 a month), making professional-grade tools accessible to hobbyists for their personal projects.

Learn more about SOLIDWORKS for Makers.

Watch the Full Video

Are you curious how James tackled the challenges of designing and upgrading a solar-powered RC plane? Watch the full video on YouTube to see the Solar 3 come to life. From power system upgrades to innovative design tweaks, you’ll see the triumphs, setbacks, and what’s next for this ambitious solar plane program.

 

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