Due to significant interest from the drone industry, customers requested an even lighter material with a density below 1 g/cm³, lighter than our existing carbon fiber–reinforced polypropylene. The goal was to further reduce the weight of UAV components while maintaining high strength and performance.

Tectonic3D developed a new material based on polyamide 11 reinforced with carbon fiber (PA11 CF), a polymer known for its good impact resistance. By incorporating the microcell technology, the material produces a controlled foaming effect during printing, resulting in a significantly reduced density of 0.85 g/cm³.

“Zephyr PA11 CF MC runs reliably on the UltiMaker Factor 4 and is ideal for drone and aerial applications. Its carbon fiber reinforcement delivers high strength and stiffness, while foaming technology enables up to 30% weight reduction. The material offers a great uniform surface finish, low moisture uptake in the material station, and is 97% bio-based. Just some of the extra's that make this material a unique material.”

ir. Jeremy Evers
Application Manager EMEA at Ultimaker