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Review
. 2025 May 24;18(11):2465.
doi: 10.3390/ma18112465.

Composite Filament Materials for 3D-Printed Drone Parts: Advancements in Mechanical Strength, Weight Optimization and Embedded Electronics

Antreas Kantaros  1 , Christos Drosos  1 , Michail Papoutsidakis  1 , Evangelos Pallis  1 , Theodore Ganetsos  1
Affiliations
Review

Composite Filament Materials for 3D-Printed Drone Parts: Advancements in Mechanical Strength, Weight Optimization and Embedded Electronics

Antreas Kantaros et al. Materials (Basel). .

Abstract

The rapid advancement of 3D printing technologies has greatly assisted drone manufacturing, particularly through the use of composite filaments. This paper explores the impact of fiber-reinforced materials, such as carbon-fiber-infused PLA, PETG, and nylon, on the mechanical performance, weight optimization, and functionality of unmanned aerial vehicles (UAVs). The study highlights how additive manufacturing enables the fabrication of lightweight yet structurally robust components, enhancing flight endurance, stability, and payload capacity. Key advancements in high-speed fused filament fabrication (FFF) printing, soluble support materials, and embedded electronics integration are examined, demonstrating their role in producing highly functional UAV parts. Furthermore, the challenges associated with material processing, cost, and scalability are discussed, along with solutions such as advanced extruder designs and hybrid manufacturing approaches that combine 3D printing with CNC machining. By utilizing composite filaments and innovative fabrication techniques, 3D printing continues to redefine drone production, enabling rapid prototyping and on-demand customization. The use of carbon-fiber-infused PLA, PETG, and nylon has demonstrated outstanding improvements in strength-to-weight performance, structural durability, and dimensional stability-key factors for enhancing flight endurance, maneuverability, and payload capacity in UAV applications. These composite materials also support the integration of embedded electronics and functional features, reinforcing their suitability for high-performance drone parts. Looking forward, future research should explore the potential of nanocomposite filaments not as a replacement but as a complementary advancement to existing composites. These materials offer opportunities for further enhancing multifunctionality, such as thermal/electrical conductivity and in situ sensing, which could expand UAV capabilities significantly.

Keywords: 3D printing; UAV fabrication; additive manufacturing; carbon-fiber-infused materials; composite filaments; drone optimization; embedded electronics; high-speed FFF; hybrid manufacturing; structural integrity.

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Conflict of interest statement

The authors declare no conflicts of interest.

Figures

Figure 1
Figure 1
Drone frame upon its fabrication process completion in a desktop FFF 3D printer (Shenzhen Creality 3D technology Co., Ltd., Shenzhen, China).
Figure 2
Figure 2
Drone frame upon the support structures’ removal process completion.
Figure 3
Figure 3
Three-dimensional printed part made out of carbon-fiber-reinforced PLA material.
Figure 4
Figure 4
FDM 3D printer with enclosed chamber.
See this image and copyright information in PMC

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