Corner Pieces for PVC Tube Drone Gate

This is my take on a connector for PVC tubes (or similar) to build a cube gate for drones. It was inspired by the Drone gate system by evilC. While that one looks quite sturdy I wanted a bit more compact version without screws to save filament - I intented to use it only for tiny whoops. It features lugs for mounting the cube somewhere with rope.

Besides the printed parts you will need:

• PVC pipes (or similar) with 25 mm outer diameter and 23 mm inner diameter, e.g. these. Because a cube has twelve edges, you will need twelve times the desired side length of the cube.
  If you scale the model appropriately it should work for other pipe diameters as well.
• Drill with 8 mm wood drilling bit
• Saw to cut the pipes to the desired length
• (optional: pipe insulation)

The socket has 1 mm of play inside the pipe. This makes for an easy installation and results in a slightly wobbly cube. It also might give a bit more way upon impact. If you want tight connections you can edit the files or scale the model up by approximately 4.5% (test print recommended). Then you might not even need to secure the pipe with the bars.

Printing

I used these settings:

• 0.2 mm layer height
• 3 walls, 4 top, 3 bottom
• 10% gyroid infill

Prints without supports, if your printer is capable of 55° overhangs

For a full cube you will need:

• 8 corner pieces
• 24 bars
• 24 clips

Additionally you can print two drilling templates, if needed.

Preparation of the pipes

• Cut the PVC pipes to the desired length (I used 48 cm, which is a 2 m pipe minus the wider connectorpart), e.g. 
• Mark drilling points 21 mm from both ends of the pipe - they need to be on the same line.
  You can put the pipe into the drilling templates and use the cutouts to mark the holes.
• Mark another set of holes on the other side of the pipe (turn it 180°)
• Drill holes with 8 mm diameter at the marke points (without the drilling template as it will become damaged as well). Wood drill bits work well. Pay special attention to your safety when drilling into a pipe!

Assembly

• Four pipes are fitted with two corner pieces each. The two remaining sockets of each corner piece must face in the same directions.
• Two of these assembled parts are connected to a square (repeat with the remaining two parts)
• Put tubes onto the sockets of one square and connect the other square
• Secure all connections with a bar and clip, if you haven't already.
  (I noticed that the clips do not hold as well as intended, so that could be optimized. Because I wrapped insulation around them, it doesn't really matter to me.)

And you're done! I added insulation for extra cushion, e.g. something like this.