Drones are becoming increasingly popular, with a wide range of diverse applications. In the past, manufacturing drones was a time-consuming process. However, manufacturing modern 3D drones is a faster and less costly process. Many hobbyists make 3D drones as their fun activity. Do you know how to make a 3D printed drone?
If your answer is no, fret not! Interestingly, manufacturing a 3D is a lot easier than you think. All it needs is the right equipment and a 3D printer, and you’ll be well-equipped to create the drone. In this article, I’ll explain 3D drone manufacturing in a few easy and practical steps. You’ll also learn the basics of 3D printing as well. So, let’s get started!
Overview of 3D Printed Drones
Before discussing the manufacturing process, let’s first understand what 3D-printed drones are!
3D-printed drones are manufactured using 3D printing technology. Their body and overall frame are made using a 3D printer. The printers use PLA or PETG Filament material and make the drones layer by layer. This printer uses computerized instructions. So, it produces a drone with the desired shape and size.
The 3D drone is the result of 3D printing, a process that utilizes additive manufacturing. It involves making the physical products in multiple layers. The 3D printers use materials and melt them. After that, it ejects the material through its nozzle present on the moving head. This nozzle moves according to the instructions we provide to the printer in G-code form.
In this way, the 3D printer makes a drone. This process is precise as it follows the computerized instructions. We create the digital design of our desired drone shape. Then, we convert the digital model or CAD design into G-coded instruction using software. Remember, the 3D printer is only compatible with G-code.
So, the printer interprets the instructions, follows them, and creates a drone by ejecting material layer by layer. Remember, 3D-printed drones still require separate electronics and their assembly for flying. The 3D printing process only creates the structure, frame, and body of these drones. Due to this technology, the creation of drones has become very fast.
How to Make a 3D-Printed Drone? Step-by-Step Process
There is no doubt that drone-making can be a tedious job. Therefore, I’ve divided the manufacturing process into six easy steps. I’ll try to explain the manufacturing process using a straightforward concept through a 3D printer. This will help newbies to grasp the whole process effectively. So, let’s get started!
1- Design or Download the Drone Frame (Digital Design)
The first step is to design the 3D model of the desired drone shape. Remember, this is the most critical step in this process. Remember, you’ll get an end product similar to this 3D model or design. If this model has imperfections, you’ll end up with 3D prints that have defects or imperfections.
Generally, CAD software is used in this step for designing the 3D models. If you have design skills, you can create the 3D model yourself. You can use design tools such as Fusion 360 or TinkerCAD. If you don’t have such skills, I highly recommend hiring a professional designer to design 3D models.
2- Convert the Design into G-Code (Printer Instructions)
As I said earlier, the 3D printers are not compatible with the CAD designs. Instead, they can interpret the G-coded instructions. Therefore, you’ll need to convert your design into G-code. In simple words, this G-code is a set of instructions for a printer. It instructs the printer on how to position its parts to create a drowner that resembles the given 3D CAD models.
The question is how to convert the CAD model into G-code. That’s where slicer software, such as Cura, comes in handy. This software can be installed on computers. You’ll need to provide your 3D CAD model, and it’ll convert the model into G-code. You can then save this G-code script for later use in the USA.
Remember, you can set some parameters while converting the 3D model into G-code instructions. Some of those parameters include:
- Layer height
- Infill density
- Infill pattern
- Printing speed
- Wall thickness
Don’t you know the value of each parameter? Worry not. Here is a table showing the standard parameter value that you can set in software like Cura. So, when you get G-code, it will have all these parameters set. The 3D printer will receive these parameters through G-code and follow them during its operation.
| Parameters Setting | Recommended Value |
| Material Type | PLA (easy for beginners) |
| Layer Height | 0.2 mm |
| Infill Density | 30% |
| Infill Pattern | Grid or Gyroid |
| Print Speed | 50 mm/s |
| Wall Thickness | 1.2 mm (or 3 walls) |
| Top Layers | 5 |
| Bottom Layers | 5 |
| Nozzle Temperature | 200°C (for PLA) |
| Bed Temperature | 60°C (for PLA) |
Remember, the table shows the most common parameter values for creating 3D drones. However, there are no hard and fast rules for using the above-stated values. You can use different values depending on your requirements and the material you use for making 3D drones. The purpose of this table is to provide a rough idea of the parameters.
3- 3D Print the Drone Frame
Once you set the value of each parameter, export and save the G-code to a USB drive. Then, feed the G-code to the 3D printer. The printer will interpret the G-coded instructions. Often, the printer’s parts move to form a 3D drone. The material will be applied to the printer bed in layers.
After a specific duration, the printer will complete the manufacturing of the 3D drone. This drone will be precisely identical to the design that you made in the first step using CAD software. Remember, this drone won’t be in working condition. Instead, it will be a structure consisting of the frame and body of the drowning. You’ll have to install other parts and components into this body. This drone is called 3D because its frame is made through 3D printing.
4- Attach the Motors and Electronic Parts
If you’ve reached this step, you’ll have the frame and body of a drone ready. Now, it’s time to install the electronics in the drones so they can function correctly. Let’s suppose you regularly drown with four arms. Here are some key electronics you’ll need:
- 4 ESCs
- 4 motors
- 1 battery
- 1 receiver
- 4 propellers
- 1 flight controller
First of all, 3D-printed the one motor on each arm of the 3D-printed frame of the drone. These motors spin the propeller, helping to generate lift and enable flight. As your drown has four arms, so install one motor on each arm. Once done, you will have to install ESCs (Electronic Speed Controllers). You can put it near each motor.
Each motor should be connected to each respective ESC. The purpose of ESC is to control the speed of motors. The next step is to install the flight controller and receiver. The flight control should fit on the center of the frame so that it connects to ESCs easily. This is the main portion of the brain of your drone.
The receiver is the key component that plays a crucial role in enabling the drone to respond to your remote controls. The last step in electronics work is to add a battery and propeller to the drone. The battery is a powerhouse, providing power to all the parts. The flight control, ESCs, and motor remain connected to the battery. You can then install the propellers that will spin, enabling the drone to fly through the air.
5- Set Up the Software
It is time to set up the software that will take drones to the next level. For this purpose, I recommend installing an app called “Betaflight” on your computer. Once installed, open this app on your computer. Now, connect the flight control present in the center of the drone to the computer.
You can establish this connection through the USB cable. Betaflight will detect the flight control system, and you can then connect the app to this system By doing so, your drone and app will be connected. Now, you’ll see a visual representation of a drone in the app.
If you generally move the drone or its propeller, you’ll see that movement on the screen as well. Turn on the transmitter or remote control and try to push the stick present on the remote control. When you move the stick, you’ll see a bar moving on the app as well. The drone will also respond to remote control. This indicates that your drone is working perfectly.
6- Test Motors & Fly Your Drone
As you are aware, each arm of the drone is equipped with a motor. If a drone has four arms, it would also consist of four motors. The spinning orientation of the motor plays a key role in the working of drones. You should ensure that two motors should spin clockwise and the other two anticlockwise. This will balance the drone when it flies in the air.
If the spinning direction is incorrect, you can swap the wires going to the ESCs. This will help connect the spinning direction of the motors. Lastly, use the remote control to fly the drone. This is still in testing mode, so fly the drone at a lower speed. If the drone flies nicely, you can then increase height and speed for extensive testing.
Frequently Asked Questions
How much does it cost to build a 3D-printed drone?
A 3D-printed drone can cost around $100 to $250, depending on its size. The electronics used in drones are expensive and add to the cost. However, if you don’t have a 3D printer, the price can go up further.
What is the best material for 3D-printed drones?
I consider PLA a suitable material for drones if you’re a newbie. However, PETG and ABS are ideal materials as they can give very durable drones. ABS material is very popular and is used at large scale.
Is it cheaper to build a 3D drone?
Yes, generally, it is cheaper if you have the skills and own a 3D printer. The cost of electronics is something that can slightly increase the price. However, if you don’t have a printer, you’ll have to outsource all the work. It would make the process less cost-effective.
Conclusion
The drones are also known as UAVs, “Unmanned Aerial Vehicles,”. They don’t require pilots and can be used for videography, photography, surveillance, and a variety of other purposes. It is no mistake that drones are costly. This offers a more affordable option for 3D-printed drones.
If you have a 3D printer, you can easily create your drones. Many people take it as a hobby and make drones for fun. However, you’ll still need some expertise and electronic parts to build a working drone. In this article, I’ve explained the entire process of drone manufacturing through 3D printing in six easy steps.