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Re: 3d printed ultralight airship

While you may not be able to print strong materials, you can distribute material smarter. You can effectively make a "material stronger"(per unit weight). Using a process called topology optimization you can find the strongest, lightest way to distribute material in a part, you can often increase the specific strength of a part by about 1.5.

Of course, this isn't the only thing you can do as Martin mentioned is wrap your prints in carbon fiber. This is actually being investigated as a means of making carbon fiber parts by the aerospace industry, as there are significant cost and time savings associated with not having to produce molds.

Though I haven't gotten much details of the exact process used, I believe they print an ultralight 3d lattice most likely produced via laser sintering(though I suppose if you sparse your prints you might get similar results), or they use a fugitive process and dissolve/melt the inside away after the resin's hardened.

Or you could just print complex connecting components for carbon fiber rods that'd you'd have hard time machining.

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