Application of the week: Custom drone component

Welcome back to our application spotlight series, where we showcase real-world 3D printed parts tackling complex engineering challenges with smart, efficient solutions.

This week, we're turning our focus to a project from Aalto University’s Design Factory, where students combined advanced design tools and additive manufacturing to create a lightweight yet durable drone component with the help of PrintShop Master and sculptor Erwin Laiho.

Developed as part of the Product Development Project (PdP) course, this custom 3D printed bracket securely mounts a module containing thermal and RGB cameras to the bottom of a drone - a critical component for a next-generation solution aimed at detecting plastic landmines in conflict zones.

Faster, lighter, mission-ready

With unmanned aerial vehicles (UAVs), every gram and millimeter counts. That’s why the team at Aalto University engineered a highly efficient camera mounting system using UltiMaker S6 and PET CF, a carbon fiber-reinforced filament known for its strength and stiffness.

The bracket involves two parts - a structural frame and a protective cover plate - Together their designed to:

• Secure the imaging hardware in place during flight
• Minimize vibrations for more stable footage
• Shield delicate components from dust, debris, and impac

Thanks to precise design iterations and slicing optimization in UltiMaker Cura, the team cut the original print time dramatically - from 10 hours down to just 3 hours and 12 minutes. Compared to legacy systems, the UltiMaker S6 proved nearly twice as fast as earlier models, while still delivering excellent surface quality and dimensional accuracy.

Key features and benefits

Here’s why this drone application stands out:

• Optimized for speed and performance Smart design and slicing techniques slashed print time by over 65%, without compromising print quality.
• Lightweight strength with PET CF Carbon fiber reinforcement delivers high rigidity with minimal weight—ideal for drones and other mobile platforms.
• Secure, vibration-resistant mounting The bracket ensures stable camera alignment, crucial for accurate mine detection via thermal imaging.
• Custom-fit solution, no tooling required Fully tailored to the drone’s geometry, the part was printed in-house with zero need for molds or external suppliers

(Source: Team Saab, https://pdp.fi/gala25/)

Functional parts that help make a difference with UltiMaker

This application is a prime example of how additive manufacturing can support life-saving innovation. Whether you're prototyping advanced tech for humanitarian work or refining drone assemblies in-house, the UltiMaker S6 paired with materials like PET CF enables you to iterate faster, print smarter, and deliver solutions that matter.

Explore how functional 3D printing can empower your next breakthrough - on the ground or in the air. Talk to our experts.