Commonly known as drones, unmanned aerial vehicles (UAVs) are vehicles that are capable of autonomous operation. As such, a drone is not limited to being an aircraft; it could be a car, boat, or even a hovercraft. However, the term has come to define an aircraft with three or more propellers that provide lift and thrust. These are also commonly referred to as multirotors or quadcopters.
In general, UAVs are mechanically very simple, consisting of a frame, a flight controller, motors, propellers, speed controllers, and possibly first-person view (FPV) equipment.
3D printing is no stranger to flight. For recreational drones, 3D printing can be a great way to make a variety of parts. These can be anything from protective bumpers and camera mounts to add-ons that bring more functionality.
In this article, we’ll be going over what to keep in mind when 3D printing drone parts, including the types of parts to print and where to find models and resources. We’ll close with a few projects to get you started. But first, why would you want to 3D print drone parts in the first place? Read on to find out!
Benefits
3D printing your own drone parts lets you create customized builds that meet specific design requirements. These parts can be quickly iterated from initial concepts to final versions, enabling rapid prototyping and testing.
In addition to being generally inexpensive (assuming you already have a 3D printer and some filament), there are other benefits to 3D printing drone parts and accessories:
- Cost-effectiveness: While the initial investment in a 3D printer and filament is required, 3D printing is generally inexpensive compared to buying brand-new parts from a retailer.
- Lightweight design: 3D printed parts can be optimized for weight reduction by adjusting parameters like perimeters and infill percentage, resulting in lighter drones with improved performance.
- On-demand production: If a part breaks, assuming you already have the filament and a printer, 3D printing enables immediate on-demand production without the need to wait for shipping or visiting a physical store. Even though many retailers offer fast delivery, it’s likely not faster than (or as satisfying as) printing the part yourself.
- More material and color options: Parts can be printed in a variety of materials and colors, allowing users to select the most suitable material with optimal mechanical properties for their specific application.
Now that you’re more excited to heat up that print bed, let’s take a look at some considerations that will help you be aware of a few important things before taking off to the skies!
Considerations
While 3D printing makes it easier to build and customize your own drones, it’s crucial to keep in mind certain factors that can affect the quality, legality, and functionality of the final product. One of the most important considerations is the weight of the parts, along with the material. It’s important to choose a strong and flexible material, as parts without flex are more likely to snap and break.
With that said, let’s take a deeper dive into these considerations!
Material
When it comes to choosing materials for drone parts, ABS, polypropylene (PP), and PETG are some of the most common options. PLA is known for its ease of use and low cost, but it lacks the strength and durability needed for most drone components. ABS offers better strength and heat resistance than PLA, making it suitable for certain drone parts, such as the frame around the battery and motors, but it can be prone to warping during printing. PP is lightweight and flexible, but it may not offer the structural integrity required for certain components. PETG provides a good balance of strength and flexibility, making it suitable for various drone components, especially those subjected to impacts or vibrations.
Carbon fiber blends, on the other hand, offer enhanced strength and stiffness, which is ideal for high-performance drone frames and other parts that require stiffness and durability. Custom frames in particular will benefit from being printed in carbon fiber-reinforced nylon. However, this material can be a bit on the expensive side.
Another popular material, especially for mini-quadcopters, is TPU. This is because it’s highly flexible and can deform on impact, absorbing energy and protecting the surrounding components. Since it’s flexible, it can also absorb vibration, reducing the amount seen in recorded footage from the drone. Thankfully, this has become less of an issue with the use of in-camera stabilization. Whether it’s OIS (optical image stabilization) or EIS (electronic image stabilization), it’s becoming a standard feature in most drone cameras. Otherwise, you can always add a gimbal to reduce photo blurriness and record smoother footage.
In addition, drone enthusiasts are now considering flexible and tough resins as emerging material options. These resins are typically more detailed and efficient than TPU, as supports can be removed quickly. Using resin can potentially decrease weight if you introduce a specific infill pattern and low density, instead of printing it all solid. However, in cold temperatures, even flexible and tough resins become brittle.
Weight
While 3D printing opens up a whole new world of possibilities in terms of additional functionality, the most important thing to bear in mind is the weight of your aircraft. Not everything that can be 3D printed and installed should be! Every gram on the aircraft has an impact on flight time and performance, especially on rotary-wing aircraft. As such, on a craft intended for longer flight times, a GoPro mount, head tracker, and drop mechanism aren’t all necessary.
In the US, regulations require registration for crafts over 250 grams. As such, the demand for quadcopters below this weight limit has increased significantly.
Additionally, companies such as DJI that sell UAVs and similar aircraft typically supply all the necessary mounts and accessories. More 3D printed parts aren’t required, as they would simply add weight.
Types of Parts
Although you can certainly 3D print an entire drone, we’ll begin by exploring various types of drone and quadcopter parts. This will allow you to easily replace damaged components or personalize your drones with custom parts. If you’re interested in 3D printing a complete drone, we’ll also provide some recommendations to guide you through the process later on.
Frame
The main parts of a drone frame, including the bumpers, camera mounts, antenna mounts, and propeller guards, are best printed in TPU. The frame is simply the base area to which the drone arms attach and it houses the core electrical components, including the battery. You can take a closer look at a drone frame in this video for the MK-3 drone, a 3D printable drone.
While it’s usually suggested to 3D print a frame for smaller drones since it experiences a lot of force, you can always choose carbon-fiber blends or as suggested by experienced makers, “straight up buy a carbon fiber frame.” Once the model is deemed finished, it can be printed in a more expensive material, such as carbon-fiber nylon, or even, if price isn’t an issue, carbon-fiber PEEK.
One way of protecting the bottom of the frame and the motor bolts is to add 3D-printed “feet”. These are especially useful when flying over surfaces such as concrete. While you could still print the feet in TPU, the abrasion resistance won’t be as good as if printed in carbon-fiber-reinforced nylon.
Propellers & Fins
If racing quadcopters is your thing, you’ll want to make sure your drone has top-mounted fins, often called Shark Fins. These are to help with a mode known as “turtle“. When landing an aircraft upside down, two of the motors can be reversed to flip the aircraft over, enabling you to take off again (and complete the race). These fins are commonly printed in TPU and occasionally nylon.
While these parts might add more weight, they enhance stability during flight through improved aerodynamics (if you consider that while designing), contribute to the drone’s aesthetics, and may also serve as mounting points for antennas. Additionally, they can aid in cooling drone components by dissipating heat effectively.
There are only a few 3D models of drone fins available on repositories, yet you can always take inspiration from them and design your own. Some good designs to look at are the shark fins for iFlight iX5 and RC Crazed 4″ Slim Phast drone, which are RC FPV racing drones.
On the other hand, a must-have part for all drones is propellers. Like fins, they are mostly drone-specific and need to be custom-designed. A nice example to check out is the YouTube tutorial from CASS Designs on custom propellers for the DJI Tello. That said, some propellers can be used on most drones and only require a little tweaking.
In addition, there are also toroidal propellers, which are characterized by their torus-shaped profile. As per an MIT paper, this design type offers potential benefits in terms of noise reduction, stability, and customization compared to traditional propeller designs.
Antenna & Camera Mounts
If you’re flying an FPV drone, video transmitter antennas are of vital importance, as they facilitate the transmission of live video feed from the drone’s camera to the pilot’s goggles or monitor. These antennas ensure a reliable and stable connection, allowing the pilot to navigate the drone effectively and enjoy a seamless FPV flying experience.
Remember, legally you must stay within the visual line of sight. For these, TPU is generally the preferred material choice because it’s highly elastic and can deform without lasting damage. However, if your drone is intended for long-range flying, encasing the active part of the antenna in TPU isn’t a good idea, as it will have a detrimental effect on the video signal.
Antenna mounts are strategically positioned on the drone’s frame to maximize signal coverage and minimize interference. You’ll find them in various designs, including fixed and adjustable mounts, allowing you to customize antenna placement based on your specific needs. Additionally, antenna mounts may incorporate features such as vibration damping to further improve signal quality and stability during flight.
While it’s easy to get camera mount designs for popular drones and cameras (DJI, Xiaomi, etc.), and drone kits, you’d probably have to make some slight changes to existing camera mounts to fit your FVP drone.
Additionally, FPV head tracking can also be enabled, where the FPV camera is mounted on a rig, enabling it to move in two or three dimensions according to your goggles. This way, the camera moves in parallel with your head, making the flight experience even more immersive. For this, you should use a non-flexible material like PETG, ABS, ASA, or even PC. Stiffness is required to eliminate play in the components, especially for high-speed movements where sudden force may bend the parts in one direction or make them swing.
Functional
If FPV flying or racing isn’t for you, you can always print drone parts for increased functionality. Perhaps a camera gimbal for aerial photography or time-lapse videos, or a mechanism to carry and drop items?
For a gimbal, the moving parts should be printed in a non-flexible material to eliminate play. However, when mounting the gimbal onto the aircraft, there should be a flexible TPU part to protect it from vibration.
For instance, the Raspberry Pi drone gimbal, a straightforward design tailored to the Raspberry Pi HQ Camera, utilizes small and cost-effective SG90 servo motors. Alternatively, you might consider Sam Pond’s meticulously crafted 3-axis gimbal for drones, which incorporates three Turnigy brushless gimbal motors and the Micro Storm32 controller.
Additionally, range extenders help improve the signal strength and range of your drone’s remote controller. These devices attach to the antenna of your controller and amplify the signal, allowing you to fly your drone farther and maintain a stable connection. Range extenders are particularly useful for FPV pilots who require an extended operating range for aerial exploration or photography missions.
Protective
Finally, you can also 3D print parts to protect your drone, such as the control sticks on the radio transmitter and casings to protect the motor, propeller, camera or gimbal, and battery.
Propeller guards are designed to shield the drone’s propellers from damage during flight, particularly in scenarios where the drone may encounter obstacles or collisions. 3D printed propeller guards are customized to fit specific drone models and can be lightweight yet robust, providing an added layer of protection without significantly impacting flight performance.
Furthermore, custom protectors (for antenna, gimbal, etc.) can help you shield parts from impact, vibration, and debris during flight. These protective covers are often designed to be lightweight and aerodynamic to minimize interference with camera operation. Interestingly, SxSierra designed a camera mount with a double guard protection cover that does its job while also giving the drone a distinct look.
Also, adding landing gear or pads to a 3D printed drone can protect delicate components during takeoff and landing, providing stability on rough terrain. However, it adds weight and complexity to the drone, potentially affecting flight performance and assembly. Consider factors like the flying environment and personal preference before deciding to add landing gear.
If you’re into FPV racing, you may also want to consider structural reinforcements such as frame braces. These can strengthen the drone’s frame and prevent flexing or bending, particularly in high-stress areas. 3D printed frame reinforcements are designed to distribute force evenly, reducing the risk of structural failure and prolonging the drone’s lifespan.
Sources for Models
If you’re looking for 3D printed models for drones and parts, you’ll want to start with an online repository like Thingiverse. Thingiverse is a great, free resource where you can find mounts for commonly available cameras (GoPro, Insta 360, etc.) and frames (TBS Source One, ImpulseRC, iFlight, among others).
GrabCAD is another free resource that tends to have engineering-focused models available. You can use the search bar to find drone models, and if you’re specifically looking quadcopter-related models, searching “quadcopter” returns quite a few results. Note that you’ll need an account to download models (not so with Thingiverse).
If you download a model from any repository (including the websites above), be sure to check the license it’s under. It may be the case that you can freely sell the model, or you may be required to credit the original designer.
If you have a specific frame and camera, often the manufacturer will have designs available to download and print. These are useful because the probability of the part fitting your frame can be higher than from a third-party website.
Designing Your Own Parts
If you can’t find what you’re looking for on an online repository, there’s always the option to make your own parts and accessories. When it comes to modeling drone parts, having the right CAD software is crucial for creating accurate, functional parts. While these programs often have a steeper learning curve, they will help you create detailed 3D models, which can then be exported as STL files for 3D printing.
While designing these parts can vary widely in complexity and function, ranging from structural components like frames and arms to intricate parts like propellers and camera mounts, you can start by tweaking existing models that are similar to what you need. Modeling these parts requires precision and attention to detail to ensure proper fit and functionality.
When choosing CAD software for modeling drone parts, it’s important to consider factors such as ease of use, feature set, compatibility with 3D printing, and price. Here are some popular CAD software options fit for modeling drone parts:
- Blender: Known for its versatility and robust feature set, Blender is a powerful and free open-source program that supports 3D modeling, sculpting, animation, rendering, and more. It offers a user-friendly interface and a wide range of tools for importing models or creating intricate designs, making it ideal for both beginners and experienced users alike. Blender’s flexibility makes it relatively simple to design drone parts, and its extensive community support provides access to tutorials and resources for users at all skill levels. To get started modeling drone parts in Blender, you can check out a helpful tutorial, such as Blender Guru’s Donut Series.
- Fusion: Developed by Autodesk, Fusion (previously Fusion 360) is a cloud-based CAD/CAM software that combines parametric modeling, mechanical design, simulation, and collaboration tools in a single platform. It offers advanced features such as parametric modeling, assembly modeling, and integrated CAM functionality, making it suitable for designing complex parts with precision and efficiency. Fusion’s cloud-based nature enables seamless collaboration among team members and provides access to powerful simulation tools for testing and validating designs before production.
- OpenSCAD: OpenSCAD is a free, script-based program for creating 3D models. It enables users to define geometric shapes and operations through code, making it a popular choice for parametric design and customizable parts. Because of this, high accuracy is ensured in the modeling of drone parts. However, it’s less suitable for organic shapes due to its reliance on mathematical expressions, making it challenging to create non-geometric forms like antenna or propeller guards.
Projects & Resources to Get Started
Whether you’re looking to dive into 3D parts for drones or basic electronics, or are seeking an entire quadcopter to 3D print, there’s a wide array of projects to explore. While you can create custom parts or even inspired replicas for commercially available drones, there are plenty of complete drone projects that are 3D print-ready with dozens of remixes. If you break any parts after a crash, a replacement is just a print away!
The 3D Printed Racing Drone – Will It Survive? is a great project to check out. In the video, the creator builds an FPV racing drone using 3D printed parts, specifically the Pion 230 with PLA. Prusa also 3D printed a small drone with a FPV camera and high-RPM brushless motors. You can find more details and the STL files for the frame in the project’s YouTube video.
Some other neat projects to check out include JohnJayMcKaye’s enhancements to the NanoLongRange drone by Dave_C_FPV or the Foldable Brushed Microquad, which is a compact yet versatile foldable drone that boasts a small form factor ideal for tight spaces. With adjustable camera angles and a convenient foldable design, it’s perfect for on-the-go exploration and aerial photography.
If you’re looking for something bigger, the T4 Quadcopter Drone offers a fully 3D printable design with easy assembly and customizable features, but it weighs around 2 kg (2.2 pounds). With a robust build and a variety of remixes available, you can tailor this drone to suit your specific needs and preferences.
And last but not least, GreatScott! demonstrates the essentials for constructing a FPV drone in his YouTube video, detailing key components like the frame, motors, propellers, and more. The original designer (andreirusu99) recommends PETG for the frame due to its superior durability, while acknowledging that nylon offers even greater strength despite its printing challenges and higher price.
Spare Parts
In addition to building complete drones from scratch, working on projects for spare parts allows you to fine-tune existing drones or replace damaged components.
Check out the following for ideas from Thingiverse on what can be printed, whether whole frames or smaller parts:
- Quadcopter: This is a frame family that can be entirely 3D printed, with dozens of makes and remixes.
- Gimbal protector: This part will help you protect the sticks on RC transmitters while in transit.
- Canopy drone: Here’s an example of a canopy that can carry a GoPro.
While parts are necessary, drone accessories are more of an add-on for convenience. The only real limitation to what you can print is your imagination! You’ll need to consider the intended purpose of both the craft and the part, as well as the impact of any additional weight.
For more DIY drone project ideas, check out Instructables. There are quite a few projects on the site, some of which incorporate 3D printed parts as well as other components such as Arduino, Raspberry Pi, or custom-designed electronics.
