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On the market, there are many types of LW-PLA available. The key difference among them is whether they are in the prefoamed or active foaming technology. Both types of filaments are well-suited for printing airplanes; however, recommended print settings will differ between them. Prefoamed filaments are typically more expensive, but they offer the potential for higher print quality and a lower risk of artifacts that may occasionally occur during active foaming printing.
How are Flightory aircraft designed?
Flightory airplanes are designed primarily for printing with LW-PLA, with additional components printed from rigid materials such as PET-G, PLA, or ABS. Each airplane has its own instructions, specifying settings for infill and wall line count for each individual part. The general rule is to print fuselages with a gyroid infill of 3%, while wings should be printed with a cubic subdivision infill of 3%. If there are any exceptions, they are noted in the instructions for a specific aircraft. Infill settings and wall thickness can be configured and changed; however, the selected settings represent an optimal compromise between the durability and strength of the airframe and its weight. The airplanes are designed to be printable on standard, inexpensive printers with a small working area. Most elements fit within a 220x220x250mm working area. Prototypes are tested on Tarantula Pro printers with a standard 0.4mm nozzle. Many users, however, choose to make modifications and experiment with other materials, such as printing whole airframes with ABS, PLA, or other harder materials. While this is possible, it should be noted that it may result in increased weight and require different settings optimized for the specific material being used.
Optimal print settings
The recommended slicer for Flightory models is Ultimaker Cura, as it offers extensive configuration possibilities and produces great printing results. Below are detailed settings for Active Foaming and Prefoamed LW-PLA. Many settings overlap, but there are specific differences in temperature, retract, and flow. If you want to use other slicers, you can experiment based on these settings. Below are the detailed print settings for Cura Slicer.
Filament used for printing Flightory prototypes
Below are the detailed print settings in the Cura slicer for active foaming and prefoamed LW-PLA. It’s important to note that the filaments used for these settings are eSUN ePLA-LW (active foaming) and Polymaker Polylite LW-PLA (prefoamed). Other manufacturers’ filaments can also be used successfully, but there may be some differences between them that might require tuning the settings, such as slight adjustments in temperature, flow, retraction, etc. Feel free to experiment and share your experiences with the community.
Active Foaming LW-PLA Settings
Quality
Layer Height
0.25 mm
Initial Layer Height
0.25 mm
Line Width
0.4 mm
Wall Line Width
0.4 mm
Outer Wall Line Width
0.4 mm
Inner Wall(s) Line Width
0.4 mm
Top/Bottom Line Width
0.4 mm
Infill Line Width
0.4 mm
Skirt/Brim Line Width
0.4 mm
Initial Layer Line Width
100%
Walls
Walls
Wall Thickness
0.4 mm
Wall Line Count
1
Outer Wall Wipe Distance
0.0 mm
Outer Wall Inset
0.0 mm
Optimize Wall Printing Order
✅
Wall Ordering
Inside to Outside
Alternate Extra Wall
⬜
Print Thin Walls
✅
Horizontal Expansion
0.0 mm
Initial Layer Horizontal Expansion
0.0 mm
Hole Horizontal Expansion
0.0 mm
Z Seam Alignment
Sharpest Corner
Seam Corner Preference
Smart Hiding
Top/Bottom
Top/Bottom
Top Surface Skin Layers
0
Top/Bottom Thickness
0.75 mm
Top Thickness
0.75 mm
Top Layers
3
Bottom Thickness
0.75 mm
Bottom Layers
3
Top/Bottom Pattern
Lines
Bottom Pattern Initial Layer
Lines
Monotonic Top/Bottom Order
⬜
Top/Bottom Line Directions
⬜
No Skin in Z Gaps
⬜
Extra Skin Wall Count
1
Enable Ironing
⬜
Skin Overlap Percentage
10%
Skin Overlap
0.04 mm
Skin Removal Width
0.4 mm
Top Skin Removal Width
0.4 mm
Bottom Skin Removal Width
0.4 mm
Skin Expand Distance
0.4 mm
Top Skin Expand Distance
0.4 mm
Bottom Skin Expand Distance
0.4 mm
Maximum Skin Angle for Expansion
90°
Minimum Skin Width for Expansion
0.0 mm
Infill (Gyroid)
Infill (Gyroid)
Infill Density
3%
Infill Line Distance
13.333 mm
Infill Pattern
Gyroid
Connect Infill Lines
⬜
Randomize Infill Start
⬜
Infill Line Multiplier
1
Extra Infill Wall Count
0
Infill Overlap Percentage
10%
Infill Overlap
0.04 mm
Infill Wipe Distance
0.1 mm
Infill Layer Thickness
0.25 mm
Gradual Infill Steps
0
Infill Before Walls
⬜
Infill Minimum Area
0.0 mm
Infill Support
⬜
Skin Edge Support Thickness
0.0 mm
Skin Edge Support Layers
0
Infill (Cubic Subdivision)
Infill (Cubic Subdivision)
Infill Density
3%
Infill Line Distance
40.0 mm
Infill Pattern
Cubic Subdivision
Infill Line Directions
⬜
Randomize Infill Start
⬜
Infill Line Multiplier
1
Cubic Subdivision Shell
0.4 mm
Infill Overlap Percentage
10%
Infill Overlap
0.04 mm
Infill Wipe Distance
0.1 mm
Infill Layer Thickness
0.25 mm
Gradual Infill Steps
0
Infill Before Walls
⬜
Infill Minimum Area
0.0 mm
Infill Support
⬜
Skin Edge Support Thickness
0.0 mm
Skin Edge Support Layers
0
Material
Material
Printing Temperature
235 °C
Printing Temperature Initial Layer
235 °C
Initial Printing Temperature
235 °C
Final Printing Temperature
235 °C
Build Plate Temperature
60 °C
Build Plate Temperature Initial Layer
60 °C
Scaling Factor Shrinkage Compensation
100%
Horizontal Scaling Factor Shrinkage Compensation
100%
Vertical Scaling Factor Shrinkage Compensation
100%
Flow
60%
Wall Flow
60%
Outer Wall Flow
60%
Inner Wall(s) Flow
60%
Top/Bottom Flow
60%
Infill Flow
60%
Skirt/Brim Flow
60%
Prime Tower Flow
60%
Initial Layer Flow
80%
Speed
Speed
Print Speed
60 mm/s
Infill Speed
60 mm/s
Wall Speed
30 mm/s
Outer Wall Speed
30 mm/s
Inner Wall Speed
30 mm/s
Top/Bottom Speed
30 mm/s
Travel Speed
120 mm/s
Initial Layer Speed
30 mm/s
Initial Layer Print Speed
30 mm/s
Initial Layer Travel Speed
120 mm/s
Skirt/Brim Speed
30 mm/s
Number of Slower Layers
2
Flow Equalization Ratio
100%
Enable Acceleration Control
⬜
Enable Jerk Control
⬜
Travel
Travel
Enable Retraction
✅
Retract at Layer Change
⬜
Retraction Distance
0.0 mm
Retraction Speed
35 mm/s
Retraction Retract Speed
35 mm/s
Retraction Prime Speed
35 mm/s
Retraction Extra Prime Amount
0.3 mm
Retraction Minimum Travel
1.5 mm
Maximum Retraction Count
90
Minimum Extrusion Distance Window
6.5 mm
Combing Mode
All
Avoid Supports When Traveling
✅
Travel Avoid Distance
0.625 mm
Layer Start X
0.0 mm
Layer Start Y
0.0 mm
Z Hop When Retracted
⬜
Cooling
Cooling
Enable Print Cooling
⬜
Regular/Maximum Fan Speed Threshold
10 s
Regular Fan Speed at Height
0.27 mm
Regular Fan Speed at Layer
2
Minimum Layer Time
2.0 s
Maximum Speed
10 mm/s
Lift Head
⬜
Support
Support
Generate Support
⬜
Build Plate Adhesion
Build Plate Adhesion
Build Plate Adhesion Type
Brim
Skirt/Brim Minimum Length
250 mm
Brim Width
8.0 mm
Brim Line Count
20
Brim Distance
0.0 mm
Brim Only on Outside
✅
Prefoamed LW-PLA Settings
Quality
Layer Height
0.25 mm
Initial Layer Height
0.25 mm
Line Width
0.4 mm
Wall Line Width
0.4 mm
Outer Wall Line Width
0.4 mm
Inner Wall(s) Line Width
0.4 mm
Top/Bottom Line Width
0.4 mm
Infill Line Width
0.4 mm
Skirt/Brim Line Width
0.4 mm
Initial Layer Line Width
100%
Walls
Walls
Wall Thickness
0.4 mm
Wall Line Count
1
Outer Wall Wipe Distance
0.0 mm
Outer Wall Inset
0.0 mm
Optimize Wall Printing Order
✅
Wall Ordering
Inside to Outside
Alternate Extra Wall
⬜
Print Thin Walls
✅
Horizontal Expansion
0.0 mm
Initial Layer Horizontal Expansion
0.0 mm
Hole Horizontal Expansion
0.0 mm
Z Seam Alignment
Sharpest Corner
Seam Corner Preference
Smart Hiding
Top/Bottom
Top/Bottom
Top Surface Skin Layers
0
Top/Bottom Thickness
0.75 mm
Top Thickness
0.75 mm
Top Layers
3
Bottom Thickness
0.75 mm
Bottom Layers
3
Top/Bottom Pattern
Lines
Bottom Pattern Initial Layer
Lines
Monotonic Top/Bottom Order
⬜
Top/Bottom Line Directions
⬜
No Skin in Z Gaps
⬜
Extra Skin Wall Count
1
Enable Ironing
⬜
Skin Overlap Percentage
10%
Skin Overlap
0.04 mm
Skin Removal Width
0.4 mm
Top Skin Removal Width
0.4 mm
Bottom Skin Removal Width
0.4 mm
Skin Expand Distance
0.4 mm
Top Skin Expand Distance
0.4 mm
Bottom Skin Expand Distance
0.4 mm
Maximum Skin Angle for Expansion
90°
Minimum Skin Width for Expansion
0.0 mm
Infill (Gyroid)
Infill (Gyroid)
Infill Density
3%
Infill Line Distance
13.333 mm
Infill Pattern
Gyroid
Connect Infill Lines
⬜
Randomize Infill Start
⬜
Infill Line Multiplier
1
Extra Infill Wall Count
0
Infill Overlap Percentage
10%
Infill Overlap
0.04 mm
Infill Wipe Distance
0.1 mm
Infill Layer Thickness
0.25 mm
Gradual Infill Steps
0
Infill Before Walls
⬜
Infill Minimum Area
0.0 mm
Infill Support
⬜
Skin Edge Support Thickness
0.0 mm
Skin Edge Support Layers
0
Infill (Cubic Subdivision)
Infill (Cubic Subdivision)
Infill Density
3%
Infill Line Distance
40.0 mm
Infill Pattern
Cubic Subdivision
Infill Line Directions
⬜
Randomize Infill Start
⬜
Infill Line Multiplier
1
Cubic Subdivision Shell
0.4 mm
Infill Overlap Percentage
10%
Infill Overlap
0.04 mm
Infill Wipe Distance
0.1 mm
Infill Layer Thickness
0.25 mm
Gradual Infill Steps
0
Infill Before Walls
⬜
Infill Minimum Area
0.0 mm
Infill Support
⬜
Skin Edge Support Thickness
0.0 mm
Skin Edge Support Layers
0
Material
Material
Printing Temperature
210 °C
Printing Temperature Initial Layer
210 °C
Initial Printing Temperature
210 °C
Final Printing Temperature
210 °C
Build Plate Temperature
60 °C
Build Plate Temperature Initial Layer
60 °C
Scaling Factor Shrinkage Compensation
100%
Horizontal Scaling Factor Shrinkage Compensation
100%
Vertical Scaling Factor Shrinkage Compensation
100%
Flow
100%
Wall Flow
100%
Outer Wall Flow
100%
Inner Wall(s) Flow
100%
Top/Bottom Flow
100%
Infill Flow
100%
Skirt/Brim Flow
100%
Prime Tower Flow
100%
Initial Layer Flow
100%
Speed
Speed
Print Speed
60 mm/s
Infill Speed
60 mm/s
Wall Speed
30 mm/s
Outer Wall Speed
30 mm/s
Inner Wall Speed
30 mm/s
Top/Bottom Speed
30 mm/s
Travel Speed
120 mm/s
Initial Layer Speed
30 mm/s
Initial Layer Print Speed
30 mm/s
Initial Layer Travel Speed
120 mm/s
Skirt/Brim Speed
30 mm/s
Number of Slower Layers
2
Flow Equalization Ratio
100%
Enable Acceleration Control
⬜
Enable Jerk Control
⬜
Travel
Travel
Enable Retraction
✅
Retract at Layer Change
⬜
Retraction Distance
6.0 mm
Retraction Speed
50 mm/s
Retraction Retract Speed
50 mm/s
Retraction Prime Speed
50 mm/s
Retraction Extra Prime Amount
0.0 mm
Retraction Minimum Travel
1.5 mm
Maximum Retraction Count
90
Minimum Extrusion Distance Window
6.5 mm
Combing Mode
All
Avoid Supports When Traveling
✅
Travel Avoid Distance
0.625 mm
Layer Start X
0.0 mm
Layer Start Y
0.0 mm
Z Hop When Retracted
⬜
Cooling
Cooling
Enable Print Cooling
✅
Regular/Maximum Fan Speed Threshold
10 s
Regular Fan Speed at Height
0.27 mm
Regular Fan Speed at Layer
2
Minimum Layer Time
2.0 s
Maximum Speed
10 mm/s
Lift Head
⬜
Support
Support
Generate Support
⬜
Build Plate Adhesion
Build Plate Adhesion
Build Plate Adhesion Type
Brim
Skirt/Brim Minimum Length
250 mm
Brim Width
8.0 mm
Brim Line Count
20
Brim Distance
0.0 mm
Brim Only on Outside
✅
These settings are intended to optimize the printing process for Prefoamed LW-PLA, ensuring a balance between print quality and material efficiency. Adjustments may be necessary based on specific printer models and environmental conditions.