Using Own Algorithms to Increase the Quality and Fatigue Resistance of FDM Printing for Use in Drones and Small Aircraft

The present article discusses the three-dimensional (3D) printing process in the fused deposition modeling (FDM) or the fused filament fabrication (FFF) technique using the author’s own philosophy of shaping the printing head path. The main requirements are the possibility of eliminating supports and reducing or even eliminating the need for the mechanical processing of 3D prints before their final assembly. The presented methodology was implemented in a computer program written by the author and was used to print typical parts used in aviation. Individual methods of shaping parts typical for the construction of small flying models, such as wings and fuselages, and methods of strengthening and connecting them have been discussed. The proposed solutions are illustrated with photos of readymade prints. This article also discusses the issues that printing high-quality parts may encounter and how to avoid them. Some attention has also been paid to the materials used for printing and their suitability in the construction of aircraft and their fatigue strength.