Getting Started with 3D Printed RC Aircraft
Zephyr Industries delivers digital 3D files you can download, slice, and print at home. That means you own the tooling — the printer and filament — while we focus on refined airframes and build documentation. This quick-start overview explains the core gear, materials, and workflow you’ll need. By the end you’ll know which printer to buy, how slicing works, what filaments go where, and where to pick up electronics and hardware to finish your build.
Already own a 3D printer? Skip to the Setup Guide for ready-to-download profiles, test prints, and step-by-step slicing instructions.
Zephyr aircraft reward stiff, accurate CoreXY motion. Any printer can work, but these platforms shorten the path to a dialed-in fleet. We list build volumes so you know when large wing panels will fit without splitting.
Bambu Lab A1
A1 (full size) — 256 × 256 × 256 mm bed-slinger with AMS support. Handles most parts for a fair price.
Bambu Lab A1 Mini
A1 Mini — 180 × 180 × 180 mm bed-slinger. Great low-cost secondary printer for smaller parts, but too small for many fuselage sections in our models.
Bambu Lab P1P / P2P / X1C
P1P / P2P — 256 × 256 × 256 mm CoreXY printers. Fast, stable, and our primary recommendation for Zephyr products. All share the same 256 mm CoreXY platform.
Bambu Lab H2C / H2D
H2C / H2D — 320 × 320 × 340 mm CoreXY workhorses. Use the extra area to queue more parts per plate and boost throughput.
Slicers transform STL/3MF geometry into G-code. They handle orientation, wall strategy, supports, and flow calibration. Our Setup Guide includes ready-to-import profiles for Bambu Studio and OrcaSlicer. PrusaSlicer users can use the detailed settings tables to manually configure profiles:
OrcaSlicer (Recommended)
Our top pick. OrcaSlicer ships new features quickly, supports both Bambu and community printers, and gives precise control over flow tuning for LW-PLA. ALthough you'll need the Bambu Connect App to connect to Bambu Printers on Desktop
Bambu Studio
Perfect if you stay within the Bambu ecosystem. One-click plate upload, remote monitoring, and AMS integration keep things convenient.
PrusaSlicer
Our JSON profiles are not compatible with PrusaSlicer—use the detailed settings tables on the Setup Guide page to manually create your filament and process profiles for LW-PLA and PLA+.
Your download may include both STL and 3MF archives. STL files are neutral meshes you can rotate however you like; 3MF plates preserve our preferred orientation, bed layout, and sometimes pre-generated supports. Some 3MF files also include pre-placed modifiers—localized zones with increased infill density or wall count for reinforcement at critical stress points. For these, simply load the 3MF, select your filament and process profiles, and slice—the modifiers are already configured. Follow this loop every time you print a new airframe:
| 1. Download | Grab STL or 3MF files from your Zephyr order. STL = single-part geometry, 3MF = ready-to-slice plate with orientation and supports. |
| 2. Import | Open the file in OrcaSlicer (or your slicer of choice). Confirm your printer profile and filament presets. |
| 3. Tune | Set temperatures, flow rates, and infill based on our build guides. New to this? Download our pre-tuned profiles from the Setup Guide instead of manually entering 40+ settings. |
| 4. Slice | ‘Slicing’ converts geometry into layer-by-layer toolpaths the printer understands (G-code). Preview walls, supports, and estimated weight. |
| 5. Print | Send G-code to the printer (USB, network, or SD). Monitor first layers to ensure adhesion and correct foaming for LW-PLA. |
| 6. Assemble | Dry-fit parts, bond with thin/medium CA glue, add hot glue fillets where vibration lives, and install electronics. |
Different parts of a plane demand different mechanical properties. Lightweight foaming, flexible hinges, and rigid mounts work together to manage flight loads and landings:
Ready to print? Our Setup Guide includes dialed-in LW-PLA and PLA+ profiles for 14 printer models— download, import, and start printing test parts in minutes.
LW-PLA Airframes
Lightweight foaming PLA that expands ~30–50% when heated. Prints matte, sands easily, and keeps wings under the 250 g threshold.
PLA+ Surfaces
Toughened PLA for control surfaces and mounts. Rigid, slightly flexible, and bonds well with CA glue for hinge shells.
PETG Mounts
High impact resistance, durability, and higher glass transition temperature for motor mounts, flexure connectors, snap brackets, and battery trays.
TPU Hinges
Shore 95A rubber-like material. Feels like flexible phone case plastic and acts as living hinges, dampers, and nose protectors.
Standard PLA
Regular PLA is easy to print but brittle. Limit it to jigs, templates, or cosmetic pieces — PLA+ offers far better impact resistance for flying hardware.
Adhesives
Medium CA glue bonds airframe parts. Hot glue secures servos in some models (M2 screws in others)
RC aircraft rely on precise servos, efficient EDFs, and balanced power systems. Windcatcher RC is our preferred partner for vetted electronics, carbon spars, and filament — making it simple to source everything in one cart.
Motor & Prop Combos
Prop-driven models ship with a tested motor + prop combo. Start with our recommendation or use tools like eCalc to explore more options Input our baseline into eCalc, adjust voltage, prop diameter, or KV to match your flying style. Remember: Zephyr kits include recommended setups in the manual — you source the hardware that fits your goals.
Servos
We recommend metal-gear EMAX and DSPower servos. They absorb landings without stripping gears and keep control surfaces centered. Metal gears shrug off hard landings and keep control linkages tight over hundreds of flights.
EDF Units
Zephyr jets spec XFly EDF units. Their dense blade count sounds fantastic and balances thrust with efficiency across 30–64 mm classes. Listen to any of our flight videos and they often sound similar to a turbine jet
ESC & Power
Choose the correct size based on the amp draw of your motor. Recommendations are in the manual and product pages. Check each build manual for minimum ESC size and connector recommendations.
Carbon Rods & Hardware
Plan for magnets, carbon spars, and pushrods — diameters vary per aircraft. Check each build manual before ordering hardware. Confirm magnet counts, carbon diameters, and pushrod lengths in the build manual before you order.
Pick the control stack that matches your flying goals. Simple three-axis gyros keep launch and landing drama-free, while full autopilots unlock waypoint navigation, return-to-home, and telemetry. We include mounting provisions in every kit so installation is painless.
HobbyEagle Gyros
A3 Mini provides launch-friendly Angle mode and switchable gyro stabilization for windy days on compact airframes. A3S4 adds extra channels for thrust vectoring and flaperons on larger jets — both configure via simple transmitter switches.
HobbyEagle GyrosINAV / ArduPilot
SpeedyBee F405 Wing and Wing Mini boards run INAV or ArduPilot for advanced flyers. Ventus Pro and Velora Pro include trays for the full F405 Wing; Velora Mini is designed around the Wing Mini. Use INAV for assisted flight modes, GPS, and telemetry.
SpeedyBee Wing SeriesSetup Resources
Join the INAV Fixed Wing Facebook community to ask questions about configuring INAV on Zephyr Industries aircraft, compare tuning notes, and download community-presets tailored for SpeedyBee wings.
Join the INAV Wing CommunityJust getting started with 3D printing? The Setup Guide walks you through downloading profiles, printing test parts (F-87 nozzle), verifying your settings, and learning advanced techniques like modifiers.
Ready to build a full aircraft? Browse the shop for complete aircraft files—each includes STL/3MF packages, build manuals, and electronics lists.