3D Printing
Nylon is hygroscopic—it absorbs moisture from the air. Wet nylon produces weak, ugly parts. This guide covers proper handling.
Recommended Filament
The 3MF files are configured for Fiberon PA6-CF (carbon fiber reinforced nylon). This filament provides the strength and stiffness required for the Replicant frame.
Why PA6-CF:
- High tensile strength from carbon fiber reinforcement
- Excellent layer adhesion
- Consistent diameter for reliable printing
- Pre-dried spools reduce prep time
Other CF-Nylon filaments may work, but print settings will need adjustment.
The Golden Rule - DRY YOUR FILAMENT!
If you're not sure it's dry, dry it again.
Wet nylon = weak parts + ugly supports + failed prints.
Fiberon PA6-CF20 Printing Guide
For complete specifications, see the Fiberon PA6-CF20 Technical Data Sheet
Why PA6-CF20 for Drones
For high-stress printed drone parts, carbon-fiber reinforced Nylon 6 (PA6-CF20) delivers exceptional performance:
Key Benefits:
- Stiffness: X-Y Young's modulus ~8636 MPa keeps arms rigid and flight behavior consistent
- Strength: Outstanding layer adhesion resists impact delamination
- Heat Resistance: Heat deflection temperature 173°C @ 1.8 MPa
- Durability: Better real-world handling than PLA-type materials
Critical Consideration: PA6 is moisture-sensitive. Performance drops dramatically when wet—dry-state tensile strength (109 MPa) falls to ~55 MPa when saturated.
Drying & Storage
Drying: 100°C for 10 hours before printing (critical for consistent performance)
Storage: Keep dry (RH < 20%). Use vacuum bags with desiccant or a dry box. Re-dry exposed spools.
Why Strict? Equilibrium moisture absorption is ~3.3%. Wet material shows 70%+ reduction in mechanical properties.
Print Settings (PA6-CF20 Optimized)
| Setting | Value | Notes |
|---|---|---|
| Nozzle Temp | 280–300°C | Higher than standard nylon for CF reinforcement |
| Bed Temp | 40–50°C | Low to prevent oozing, use adhesion promoter |
| Chamber | Room temp | No heated chamber required |
| Part Cooling | OFF | Essential for proper layer bonding |
| Print Speed | Up to 300 mm/s | Printer-dependent, use as upper bound |
| Supports | PolyDissolve™ S1 | Recommended for easy removal |
Equipment Considerations
Recommended Printer: Bambu Lab P1S or P1P — all 3MF files are pre-configured for Bambu Studio. Other printers capable of CF-Nylon (high-temp hotend, hardened nozzle) will work but require manual settings adjustment.
Nozzle: Use hardened steel or ruby. Brass wears out in ~9 hours due to abrasive carbon fiber.
Adhesion: Apply thin layer of glue stick to textured PEI surface. Low bed temperature prevents oozing.
Post-Processing
Annealing: 100°C for 16 hours after printing (matches datasheet test conditions for optimal stability)
Support Removal: Remove supports promptly to prevent moisture-induced bonding
Bed Adhesion
Nylon requires extra adhesion help:
- Glue stick - Thin, even layer (Elmer's purple works)
- Clean bed - IPA wipe before glue
- Textured PEI - Better than smooth for nylon (engineering plate recommended)
- Brim - 5mm brim for large parts
Print Order
Optimized print sequence for efficient workflow:
- Arm Bosses - Start with these small parts
- Motor Mounts - Print next for assembly
- Assemble and bond the arms while Chassis Core is printing (time saver)
- Chassis Core - Largest, most complex (print while assembling arms)
- Battery Rails - Print last (CF-Nylon)
Nose Cone: Change to 0.6mm nozzle for TPE flexible filament
3MF Files & Print Previews
The following 3MF files are pre-configured for Bambu Studio with optimized settings, supports, and orientations for reliable CF-Nylon printing.
Arm Bosses
The foundation of each arm assembly - these precision-machined nylon bosses provide the mounting interface between carbon fiber tubes and motor mounts.
Download: Arm Bosses 3MF | All STEP Files (ZIP)
Print these first - small, fast prints that establish your material and settings before committing to larger parts.
Motor Mounts
High-strength motor mounting brackets with integrated epoxy injection ports for superior carbon fiber tube bonding.
Download: Motor Mounts 3MF | Motor Mount STEP
Complex internal channels ensure complete epoxy distribution around the carbon tubes for maximum bond strength.
Chassis Core
The structural heart of the Replicant - this monolithic chassis core houses all electronics and provides mounting points for arms, battery, and payload.
Choose the appropriate chassis version based on your flight controller USB port orientation:
- Left USB Version - USB port faces left when viewed from above
- Right USB Version - USB port faces right when viewed from above
Both versions are compatible with 20x20mm and 30x30mm flight controller stack sizes.
The largest and most complex print - features integrated cable management, vibration isolation, and precise mounting tolerances.
Battery Rail Male
Precision battery mounting rail with integrated securing features and vibration isolation mounts.
Download: Battery Rail Male 3MF | Battery Rail STEP
Critical for secure battery mounting and optimal center of gravity positioning.
Nose Cone 04 Mount
Material: Spidermaker TPE (Matte Black) - Flexible filament requiring specialized printing techniques.
Key TPE Printing Requirements:
- Direct drive extruder - TPE's elasticity requires direct filament feeding to reduce friction
- Direct filament feeding - Take the top of the printer and place the reel immediately adjacent to the print for optimal TPE feeding
- 0.6mm nozzle - Essential for proper flow control with flexible filament
- Thorough drying - Dry at 50°C for 8-12 hours before printing
TPE Print Settings:
- Temperature: 230-250°C
- Bed Temp: 40-50°C
- Print Speed: 30-50 mm/s
- Supports: PVA water-soluble
- Retraction: Minimal
TPE printing differs significantly from nylon. These settings were developed through extensive testing to ensure reliable results.
Download: Nose Cone 04 Mount 3MF | 04cm Mount STEP
Flexible mounting bracket designed for vibration dampening and precise GPS antenna positioning.
These 3MF files include:
- ✅ Optimized print orientation for strength
- ✅ Automatic support generation
- ✅ Bambu Studio-specific settings
- ✅ CF-Nylon material profiles
- ✅ Quality assurance checkpoints
STEP Files
Additional STEP files for CAD design, modification, and analysis:
- Complete STEP Package (ZIP) - All STEP files in one download
- Chassis Core Left USB - Left USB orientation chassis
- Chassis Core Right USB - Right USB orientation chassis
- Bottom Plate - Base mounting plate
- Top Plate Brace - Upper mounting plate brace
- Upper Shell - Protective housing
- Spine - Structural backbone
- 04cm Mount - O4 Pro camera mount
Support Removal
Tree supports work well for nylon. After print:
- Let part cool completely
- Start at support root/base
- Use flush cutters, don't rip
- Take care around internal channels
Quality Check
Before assembly, verify:
✅ No visible porosity or bubbles
✅ Layers fully fused
✅ No warping or lift
✅ Supports removed cleanly
✅ Dimensions within tolerance
Top Cover (SLA Resin Printing)
The top cover is printed using stereolithography (SLA) technology with tough resin. While the original specification calls for an Asiga Pro 4K printer (a powerful professional-grade SLA machine), many modern SLA printers can produce this part faithfully.
Recommended SLA Alternatives:
- Phrozen Sonic Series: Mini 8K or Sonic Mega 8K - excellent value and performance
- Formlabs: Form 3 or Form 4 - professional-grade reliability
- Other modern SLA printers with 4K+ resolution and tough resin compatibility
SLA provides exceptional surface finish and dimensional accuracy required for the final enclosure.
Why SLA for the top cover:
- Precision: 4K resolution ensures perfect fitment with the chassis
- Surface quality: Smooth finish without layer lines
- Material properties: Tough resin provides durability and weather resistance
- Complex geometries: Supports fine details and internal features
Recommended Resin
Tough/Engineering Resin suitable for your SLA printer (Asiga Tough, Formlabs Tough, or equivalent):
| Property | Specification | Importance |
|---|---|---|
| Viscosity | 200-500 cps | Print reliability |
| Tensile strength | >50 MPa | Impact resistance |
| Elongation | >10% | Ductility |
| Heat deflection | >60°C | Thermal stability |
Print Settings (General SLA)
| Parameter | Value | Notes |
|---|---|---|
| Layer height | 50-100μm | Balance speed vs. quality |
| Exposure time | 8-12s per layer | Material-dependent |
| Lift speed | 6-8 in/s | Minimize distortion |
| Light-off delay | 1-2s | Allow resin flow |
Post-Processing
Proper post-processing is critical for resin parts:
- Washing: 5-10 minutes in isopropyl alcohol (IPA) bath
- Curing: UV light exposure for 10-20 minutes per side
- Support removal: Use flush cutters, avoid damaging part
- Sanding: 400-1000 grit for smooth mating surfaces
Uncured resin remains soft and will degrade over time. Always cure parts completely before assembly.
Quality Verification
Before assembly, inspect the top cover:
✅ Dimensional accuracy - Verify all mounting points align
✅ Surface finish - No uncured resin or rough spots
✅ Internal features - Cable channels and mounting bosses intact
✅ Fit test - Dry fit with chassis before final assembly
Common Issues
| Problem | Symptom | Solution |
|---|---|---|
| Incomplete cure | Tacky surface | Extend UV exposure time |
| Distortion | Warped features | Adjust lift speed/settings |
| Poor adhesion | Part separates from build plate | Clean build plate thoroughly |
| Support marks | Scratches on surface | Careful support placement |
Next Steps
- CAD Downloads - Get 3MF files
- Parts List - Order components
- Arm Bonding - Start assembly