Designing and Printing a Custom FPV Drone Carry Case
Transporting FPV gear is always a challenge. Goggles, transmitter, batteries, tools, spare props, and the quad itself all need to survive car rides, hikes, and airport baggage handlers. Commercial cases like the Pelican 1510 or Harbor Freight Apache 3800 work, but they are heavy and rarely fit FPV equipment perfectly. A 3D printed custom insert transforms a generic hard case — or even a backpack — into a precision-fit transport solution.
Why 3D Print Instead of Pick-and-Pluck Foam
Pick-and-pluck foam is the default for many pilots. It works, but it degrades: the foam cubes tear out unevenly, the remaining foam breaks down with repeated use, and the fit is approximate at best. A 3D printed insert is cut exactly to the shape of your gear. You can include finger cutouts for easy removal, label each slot with embedded text, and design compartments that hold spare parts securely.
3D printed inserts are also lighter than multiple layers of dense foam. For pilots who hike to mountain flying spots, shaving 300 grams from the carry case matters.
Designing the Insert in CAD
Start by measuring every piece of gear you want in the case: quadcopter (with props removed or folded), transmitter, goggles, battery packs, charger, prop bag, and tool kit. Photograph each item on a cutting mat with grid lines for scale reference. Import the photo into Fusion 360 as a canvas, calibrate to the grid, and trace the outline with the spline tool. Offset the outline by 1 mm to 1.5 mm for a snug but not tight fit.
For the quadcopter slot, model a recess that cradles the arms and the center stack. Include a pocket for the VTX antenna to extend upward or fold sideways. For LiPo batteries, design individual slots with finger notches so you can pull each pack out without prying. The transmitter slot should accommodate the neck strap, gimbal protectors, and any extended antenna.
Printing in Sections
Most 3D printers have a build volume of around 220 x 220 mm, which is smaller than a typical hard case interior. Split the insert into interlocking sections using dovetail joints or puzzle-piece connectors. Print each section flat on the bed. PLA is perfectly adequate for indoor-stored cases; PETG offers better heat resistance if the case might sit in a hot car.
Print settings: 0.3 mm layer height for speed, 3 perimeters for strength, 15% gyroid infill. A full insert for a 480 x 360 mm case prints in about 20 to 25 hours across 4 to 6 sections, consuming roughly 500 to 700 grams of filament.
Assembly and Finishing
Glue the sections together with CA glue along the dovetail joints. Optionally, spray the entire insert with Plasti Dip for a rubberized grippy surface that holds gear in place. Add a desiccant packet compartment in a corner to manage moisture. Label each slot with a label maker or embedded text printed directly into the insert using a filament color change at the top layer.
Alternative: Gridfinity for FPV
The Gridfinity system — originally designed for tool organization — adapts surprisingly well to FPV gear. Print a Gridfinity base plate sized to your case, then design or download FPV-specific bins: battery holders, prop bins, and quad cradles that snap into the grid. The modular approach lets you reconfigure the case for different flying sessions without reprinting the entire insert.
How do you transport your FPV gear? Show us your case setup in the comments!