Custom Drone Frame Prototyping
As part of a student-led engineering project, a team from the Robotics Club designed and fabricated a custom lightweight drone frame using the FabLab’s 3D printers. The goal was to create a durable yet flexible structure that could support four brushless motors, a camera, and a flight controller — while keeping the total weight under 250 grams.
Difficulty level :
Difficult
Supplies
- Machine: Prusa i3 MK3S+ 3D printer
- Material: PETG filament (1.75 mm)
- Software: Fusion 360, PrusaSlicer
Step 1 : Concept and Design Phase
- The students began by sketching initial concepts and defining specifications (size, weight, motor layout, payload capacity).
- Using Fusion 360, they modeled individual parts: arms, central plate, and landing gear.
- Parameters such as hole spacing, arm thickness, and assembly joints were defined using parametric constraints, allowing fast adjustments later.
- A basic aerodynamic simulation helped verify that the arm geometry would minimize drag and vibration.
Step 2 : Simulation and Optimization
- The 3D models were tested in Fusion 360’s simulation workspace using static stress analysis.
- The team compared different geometries (solid vs. honeycomb) to find the best balance between stiffness and material usage.
- Weak points were reinforced and unnecessary volume was removed to reduce weight.
Step 3 : Slicing and Print Preparation
- Each part was imported into for slicing and toolpath generation.
- Printing parameters were selected based on mechanical requirements:
Material: PETG (chosen for flexibility and heat resistance) Layer height: 0.2 mm for precision and speed balance Infill: 40% gyroid pattern for strength Perimeters: 3 shells for impact resistance - The total estimated print time for one drone was 9 hours across four separate prints.
Step 4 : Fabrication and Printing
- The parts were printed on the Prusa i3 MK3S+ 3D printer under staff supervision.
- During printing, students monitored the first layers to ensure proper adhesion and temperature stability.
- Each finished part was inspected for defects (warping, layer separation, or stringing).
- Minor adjustments (bed leveling, retraction settings) were made between runs to improve quality.
Step 5 : Post-Processing and Assembly
- After printing, the components were carefully cleaned and sanded at joint points for a perfect fit.
- The arms and plates were assembled using M3 aluminum screws, carbon rods, and nylon spacers.
- Motor mounts and the flight controller bracket were added using printed adapters.
- Wiring was routed internally through hollow sections designed during the modeling stage.
Step 6 : Final Results
- Weight: 235 g (frame only)
- Material used: 180 g PETG
- Cost per prototype: ≈ $6
- Print time: 9 hours
- Flight duration: 12 minutes per battery
- The final frame design was fully modular and repairable — a damaged arm could be reprinted in less than 2 hours.
