Material selection is the main challenge in the drone industry. In this study, hardness, abrasive wear, impact resistance, tensile strength, and durability (frost resistance and accelerated ageing) were identified as important characteristics of drone materials. The additive manufacturing technology was used to produce the drone leg specimens and prototype. The suitability of PETG as a primary filament material in the design of the drone leg was investigated. Nine series were printed with different raster lines (0.1, 0.2 and 0.3 mm) and infill densities (30, 60 and 90%). Printed specimens were annealed in salt and alabaster, as well as immersed in liquid nitrogen. Series with raster line-infill densities of 0.1–30, 0.3–30, 0.1–90 and 0.3–90 were identified as the most interesting ones. Thermally treated specimens had better mechanical and durability properties, and infill density was found to be the most important printing parameter. Specimen annealed in salt with a raster line of 0.1 mm and infill density of 90% had the best results. Since ABS is the most common material used for drone leg production, its properties were compared with the PETG specimen, which showed the best properties. The potential of PETG as an alternative material was proven, while the flexibility, productivity and suitability of the leg drone design were additionally confirmed.

The 3D printing parameters are known to have a significant impact on manufactured parts, and the layered morphology of these parts makes mechanical design analysis for engineering applications difficult. In this work, the tensile strengths and microhardness of 3D printed polylactic acid (PLA) specimens with different orientations and numbers of individual layers of mesh material (polyvinyl chloride – PVC) were investigated as a laminate composite. Composite specimens were obtained using 3D printing via fused deposition modelling (FDM). Moreover, the influence of printing parameters (i.e. infill density and layer height) and the number and orientation of reinforced meshes on the mechanical response was investigated. Fracture strength of PLA/PVC laminate composites ranges from 31.30 MPa (3 PVC mesh layers; mesh height position: 25 %│50 %│75 %; infill density: 60 %; PVC mesh orientation: 90°│45°│90°; layer height: 0.2 mm) to 18.62 MPa (without PVC mesh; infill density: 30 %; layer height: 0.1 mm) demonstrating a significant impact of the number of the PVC mesh layers, infill density of PLA and layer height on the final mechanical parameters of printing PLA/PVC elements. The surface hardness at the micro load level showed that the number of reinforcement layers affects the microhardness value, as well as material filling and mesh orientation. The specimen with the following parameters gave the best results: layer height: 0.2 mm; 3 PVC mesh layers; infill density: 60 %; PVC mesh orientation: 90°│45°│90°. The average hardness values for one layer and three layers of mesh were in accordance with tensile test results.

This study investigates the thermomechanical resistance and electrochemical behaviour of a composite coating, based on a thermoplastic polymer, poly(vinyl butyral) (PVB), known for its great adhesion to various surfaces, with incorporated single-layer graphene nanoplatelets. Composite coating samples are produced by solvent-casting technology, in form of thin films in teflon moulds for the mechanical and thermal analyses, and on a thin carbon mat as a coated carrier for experimental electrode specimens. By employing Fourier-transform infrared spectroscopy the interaction of the incorporated graphene nanoplatelets with the polymer matrix is examined. Differential scanning calorimetry is applied to examine the thermal resistance of the hybrid material. For the obtained polymer/graphene films, mechanical properties are determined: indentation hardness and tensile strength. Electrochemical properties of the samples are investigated by cyclic voltammetry. Results obtained for samples with graphene nanoplatelets are compared to neat polymer and neat carbon mat and indicate that the inclusion of graphene significantly improves the materials’ thermomechanical resistance and their potential for use as an electrode material in electrochemical energy storage devices. These findings suggest that PBV/graphene composites and coatings are promising materials for advanced electrochemical applications.

A novel epoxy/poly(vinyl butyral) (PVB) hybrid composite reinforced with nano-boron carbide (B₄C) particles has been developed to explore its potential for high-performance protective coatings and structural applications. Boron carbide, known for its exceptional hardness, wear resistance, and thermal stability, is incorporated into the polymer matrix to enhance mechanical durability, impact resistance, and erosion resistance. B₄C-based composites have also found application in electrochemical energy storage devices due to their chemical stability, electrical conductivity, and corrosion resistance. A comprehensive characterization of the composite includes scanning electron microscopy (SEM) to assess nano-B₄C dispersion and morphology, differential scanning calorimetry (DSC) to evaluate thermal stability and phase transitions, and Fourier-transform infrared spectroscopy (FTIR) to investigate chemical interactions within the polymer matrix. The mechanical performance is examined through hardness testing, Charpy impact testing, and ultrasonic cavitation resistance measurements, providing insight into the composite’s ability to withstand dynamic loading and erosive environments. The results demonstrate that nano-B₄C reinforcement significantly improves impact resistance, surface hardness, and cavitation durability, positioning these composites as promising multi-functional materials for potential use in abrasion-resistant coatings, ballistic protection, and aerospace applications, but also in electrochemical industry.