Drone and RC Parts: Printing for Aerial Applications

Logan F.

Taking 3D Printing to the Sky

The drone and RC vehicle communities have embraced 3D printing with particular enthusiasm, and for good reason. Australian hobbyists and commercial drone operators regularly print custom frames, camera mounts, propeller guards, antenna holders, motor protectors, and payload release mechanisms. The combination of design freedom, rapid iteration, and on demand production makes 3D printing uniquely suited to the needs of aerial platforms, where one off custom geometry is common and commercial off the shelf parts rarely fit exactly.

Aerial applications place specific demands on materials and design. The paramount concern is weight; every gram of additional weight reduces flight time, payload capacity, and performance. The second concern is structural integrity, as aerial failures are not just inconvenient; they're often expensive (replacement electronics, replacement drone) and potentially dangerous (a falling multirotor from height). These twin requirements provide minimum weight and adequate strength and define the design optimisation challenge for drone parts.

Material Selection for Aerial Components

PLA-CF is the ideal starting material for most structural drone components. Its stiffness to weight ratio is excellent and is comparable to or better than equivalent geometry PETG at a meaningfully lower weight per volume. For crash resistant components (landing feet, propeller guards, and arm bumpers) where the material must absorb impact energy rather than transmit it, 95A TPU is unmatched; it deforms dramatically on impact and recovers, protecting expensive electronics from damage.

Avoid plain PLA for structural drone frames, as its brittleness under sudden impact (typical in crashes) makes it a poor choice for primary structure. PETG is acceptable but heavier than PLA-CF for equivalent stiffness. For performance-critical applications where weight is absolutely paramount, PA-CF provides the highest performance, but the printing complexity is significant. See our CF composite guide for a detailed material comparison.

Design Principles for Aerial Parts

Wall count over infill: for drone structural parts, 4–6 walls at 10–15% gyroid infill outperforms 2 walls at 50% infill in most load cases. The outer walls take bending and torsion loads; the infill primarily supports the top surfaces and resists compression. Use minimum material in non structural regions and maximum wall count in structural members. Orient prints so bending loads act along the XY plane (within layers) rather than the Z axis (between layers). Drill holes and wire channels into the design model rather than cutting them post print, as post print drilling FDM parts often causes delamination cracks.

Testing Protocol: Non-Negotiable

Never fly a 3D printed structural component without bench testing it first at loads exceeding expected flight loads. Mount the motor on a test bench, run it to maximum throttle, and verify the printed mount doesn't deflect, crack, or fail. Test at 150% of expected maximum load, as this procedure provides a safety factor for unexpected conditions. Inspect all printed parts under bright light before every flight; even a faint crack initiated by a previous hard landing may propagate catastrophically on the next flight. See our under extrusion guide for how to ensure your parts are fully dense before they go airborne.