AeroTetris is a brand specializing in the production of innovative kits for the assembly of radio—controlled (RC) aircraft models made of expanded polystyrene (styrofoam). 

Their uniqueness lies in the "tetris" ("puzzle") method: The model consists of many parts that form cross-sections (layers). The layers are glued together, forming a strong and lightweight frame of complex shape. Another name for the technology is Layer-by-layer prototyping.

  The "puff pastry" design: Instead of the traditional large pieces of foam, dozens of parts are used, cut on a CNC machine, which allows for high detail and replicability of aircraft.

The company offers a huge selection of kits, from compact to gigantic (with a wingspan of more than 3 meters). Materials: Extruded polystyrene foam (XPS) is used, which is usually glued with fiberglass or paper after assembly to provide rigidity and finishing.

  DIY: 

AeroTetris kits are aimed at experienced modelers, as they require perseverance when gluing together multiple segments and self-installing all electronics (motors, servos, control systems).

  Popular models

Their catalog includes both civilian and military aircraft, including:

Jet fighters: Lockheed SR-71 Blackbird, Su-27, Su-30, F-15E, F-16, MIG31, MIG41, Dassault Rafale, Eurofighter Typhoon EF2000.

Transport and training aircraft: An-225 Mriya, Lockheed C-130 Hercules, Aero L-39 Albatros.

Gliders and civil aviation: Learjet 31/35, Douglas DC6B, Airbus A-320, Boeing-727, Ventus 2cx, Arado 196.

  Where to find

Production is currently located in Spain. Official website: aerotetris.com — here you can view the full catalog, prices and assembly instructions. Community: Discussions of assembly processes are often found on major modeling forums such as RCGroups, RC-network, RCScaleBuilder or ModelFlying.

[1] This Company Will Sell You a Giant Foam An-225

[2] If you love making RC planes, then check out these foam replica planes

[3] Design and Approach of CNC Foam Cutter

[4] ARDUINO CNC HOT WIRE CUTTER

[5] academia.edu

[6] Thesis for: Bachelor Engineering Advisor: Jouni Könönen Authors: Luka Ivanovskis

References

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  1. The Drive
  2. Interesting Engineering
  3. Researchgate Design and Approach of CNC Foam Cutter
  4. ARDUINO CNC HOT WIRE CUTTER
  5. Academia. Design and Development of CNC Foam Cutter
  6. Researchgate. Four Axis Hot-Wire Foam Cutter Controlled by Mindstorms EV3