Watch: Beginner develops 3D-printed drone that could fly 130 miles in 3 hours

First-time maker’s drone

Xu’s project, completed in just 90 days, was executed without any formal background in aerodynamic modeling, 3D printing, or computer-aided design (CAD), a claim he substantiates through a detailed build log and a video presentation on YouTube. 

The drone was built entirely from scratch, with no pre-existing airframe or commercial design used as a reference. 

Xu took a bottom-up approach, designing, modeling, and printing each aerodynamic surface and structural component himself.

The airframe was printed using a Bambu Lab A1 3D printer, a desktop device Xu used to manufacture the composite parts required for the drone’s airframe and flight surfaces. 

The printer, previously rated 4.5 out of 5 stars in independent reviews, was the backbone of the prototyping effort, enabling Xu to iterate rapidly on complex aerodynamic shapes.

Critical non-printable elements, including radio equipment, motors, and electronic speed controllers (ESCs), were sourced separately.

However, Xu integrated these systems, including power management and control algorithms. 

The drone’s propulsion and endurance were made possible using a high-energy-density lithium battery, significantly extending mission duration compared to standard FPV systems.

130-mile range

With a wingspan optimized for efficient glide and a robust VTOL propulsion configuration, the drone achieved its notable endurance through aerodynamic efficiency and power optimization. 

Xu estimates the maximum endurance to be around 3 hours under ideal conditions, allowing the aircraft to cover up to 130 miles (209.2 km) on a single charge.

The winged VTOL design allows for vertical launch and recovery without needing a runway while transitioning to efficient forward flight once airborne, a capability typically reserved for much more advanced military or commercial unmanned aerial systems (UAS). 

Xu’s build demonstrates how consumer-accessible technologies rapidly erode the gap between hobbyist experimentation and advanced aerospace development.

While Xu did not provide a full technical breakdown or open-source plans, he emphasized that steep learning curves shaped the build process. 

These included understanding the basics of flight dynamics, sourcing components from various vendors, and identifying design failures during the printing and assembly. 

The result is a fully functional VTOL drone with strategic endurance, entirely self-built from digital model to first flight.

The timing is notable. Xu’s effort coincides with broader institutional interest in 3D printing and drone integration. 

The U.S. Army recently announced expanded initiatives to incorporate additive manufacturing and autonomous systems into frontline logistics and reconnaissance. 

Xu’s civilian project echoes those trends, highlighting how low-cost, decentralized innovation is becoming a legitimate parallel to conventional defense and aerospace R&D.