Generative Design 1.5" FPV Drone Frame

This drone frame was created using the generative design feature in Fusion 360, which helps find shapes that are both lightweight and strong. Instead of designing everything by hand, the software suggests an optimized structure—resulting in a frame that looks organic, modern, and unique. The goal was to keep the weight as low as possible while still giving the drone the stability it needs in the air. 

Print Settings

For now, I’m printing the frame on a Prusa Mini+ using PETG. But, I plan to order an SLS print in 3301PA Nylon. This should make the frame even stronger, smoother, and lighter overall. 

• Supports: Yes - Be sure to remove supports inside the screw holes of the top part when slicing,                                        because they’re almost impossible to remove from a 2 mm hole. 

• Layer Height: 0.15 mm 

• Infill: 3 perimeters, 25% infill, triangle pattern

• Print orientation: Printing the frame flat on the bed gives the best strength across the arms. 

• Filament: PETG 

Required Components

The frame is designed around parts from a BetaFPV Femto. Here are the components I used:

• FC:  F4 2-3S 20A AIO FC

• Camera and VTX: DJI O4 Air Unit

• Motors: LAVA 1102|14000KV

• Propellers: Gemfan 1611 3-Blade Propellers (1.5mm Shaft)

• Battery: LAVA 2S 450mAh Battery

• M2x8mm Screws for the frame. The rest is repurposed from the Femto 
  

Change Log

1. 07/12/25: added pictures

2. 08/12/25: Strengthen battery mount