What We Tested and How
We printed four identical camera mount brackets and four antenna housings in each material using matched print settings (0.2mm layer height, 4 perimeters, 40% gyroid infill). All parts were printed on a Bambu Lab P1S for dimensional consistency. No post-processing, no UV coating, no paint — bare printed parts, exactly as they come off the printer.
Parts were mounted on a south-facing bracket at 45° tilt in Toronto, Ontario (USDA Zone 6b) — receiving full direct sun exposure from late April through late July 2025. We measured dimensional drift at 30, 60, and 90 days, tested flex stiffness on a jig, and photographed surface degradation.
PETG Results: Better Than Expected
At 30 days, the PETG parts showed no measurable dimensional drift and only minor surface chalking on the most UV-exposed faces. At 60 days, we measured 0.3 mm of dimensional drift on the thinnest sections of the camera mount and visible surface crazing on both parts. At 90 days, the camera mount had developed a hairline crack along one of its thinner walls — the part was still functional but would not survive a hard landing.
The verdict on PETG for outdoor use: acceptable for short deployments (under 4 weeks) or parts that live in partial shade. For long-term outdoor exposure in direct sunlight, PETG degrades in ways that are not immediately visible but create structural vulnerability.
PETG // Standard // Outdoor Test
Polymaker PolyLite PETG
- Best all-round PETG for drone parts — consistent, easy to print
- Works on open-frame and enclosed printers from 230°C
- Good stiffness for structural parts that stay out of direct UV
- Excellent layer adhesion — strong across all print orientations
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ASA Results: Does What It Says
At 30 days, the ASA parts were visually identical to day one. At 60 days, we measured zero dimensional drift and only cosmetic surface fading (colour shift from dark grey to slightly lighter grey — no structural significance). At 90 days, stiffness tests showed no measurable change from the day-zero baseline. The parts could have stayed outdoors indefinitely.
This is exactly what ASA is engineered for: UV stabilised, thermally stable up to 95°C, moisture resistant. For any drone component that lives permanently outdoors — camera housings, GPS mast caps, antenna brackets, landing gear — ASA is the only correct choice.
ASA // UV Stable // Outdoor Rated
Polymaker PolyLite ASA
- UV stabilised — zero structural degradation at 90 days in our outdoor test
- Heat resistant to 95°C — survives summer temperatures in any climate
- Requires enclosed printer or warm environment to avoid warping
- Print at 240–260°C with heated enclosure for best results
- Available in matte finish that hides layer lines on visible drone parts
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◆ Pros
- Zero structural degradation in 90-day UV test
- Best heat resistance of any consumer filament under $30
- Matte finish looks excellent on visible parts
― Cons
- Requires enclosure — warps badly on open-frame printers
- Slightly more brittle than PETG on impact
- Fumes require ventilation — print enclosed and ventilate
◆ AeroInfill Verdict
For anything permanently outdoors, use ASA. For indoor or short-duration outdoor use, PETG is fine and easier to print. The performance gap outdoors is real and measurable — do not use PETG for camera mounts, GPS housings, or antenna brackets that live in the sun.
When to Use Each Material
Use PETG for: indoor structural parts, crash-likely components (better impact resistance than ASA), rapid prototyping, short-term outdoor use under 4 weeks. Use ASA for: permanent outdoor exposure, UV-facing housings, any part on a drone that flies primarily outdoors, motor mounts in hot climates.