Tailored Fibre Placement (TFP) for Drone Manufacturing

High-Performance Carbon Structures with ZSK Industrial Embroidery Technology

Lightweight. Strong. Intelligent. Automated.

 

With Tailored Fibre Placement (TFP) technology from ZSK STICKMASCHINEN, drone manufacturers produce next-generation carbon fibre components – lighter, stronger and more intelligent than conventional composite materials.

 

Thanks to precise, stitch-based fibre placement, ZSK machines enable automated production of load-path-optimised structures for UAV and drone applications – from arms and frames to components with integrated sensors and heating elements.

 

With Tailored Fibre Placement (TFP) technology from ZSK STICKMASCHINEN, drone manufacturers produce next-generation carbon fibre components
With Tailored Fibre Placement (TFP) technology from ZSK STICKMASCHINEN, drone manufacturers produce next-generation carbon fibre components

 

Why TFP Is Ideal for Drone Structures

Modern drones must deliver maximum performance at minimal weight. TFP meets these requirements exceptionally well.

 

Key Challenges in Drone Design

  • Strict weight constraints
  • High vibration and fatigue loads
  • Complex stress distributions
  • Limited installation space
  • Growing demand for integrated electronics

How ZSK TFP Solves These Challenges

  • Fibres follow real load paths for variable-angle composites
  • Material only where it is needed
  • Local reinforcement zones
  • Integration of functional elements
  • Fully automated, reproducible production

Result: Up to 25% weight reduction with equal or higher stiffness.

 

 

Typical TFP Components for Drones

Drone Arms & Booms

  • Optimised bending and torsional strength
  • Reduced vibration transmission
  • Higher payload capacity
  • Extended flight times

Motor & Propeller Interfaces

  • Circular fibre layouts around bolted joints
  • Local fatigue reinforcement
  • High durability at elevated rotational speeds

Central Frame & Chassis

  • Structural cut-outs without loss of strength
  • Optimised load transfer between arms
  • Integrated cable routing
  • Hybrid designs made of carbon/glass/aramid

Structural Enclosures

  • Battery housings
  • Payload carriers
  • Camera mounts
  • Sensor housings

Advantage: Fewer individual parts with higher mechanical efficiency.

 

Integrated Functional Conductor Structures: Heating, Sensors & Data Lines

Intelligent drone components with integrated monitoring and environmental control.

A unique advantage of ZSK TFP technology is the direct integration of functional conductor elements into the composite structure during production.

 

Can be integrated:

  • Heating wires (de-icing, temperature control)
  • Sensor cables (strain, temperature, vibration)
  • Data and signal lines
  • Power lines

 

Your Benefits

  • ✔ No separate wiring harnesses
  • ✔ Reduced assembly effort
  • ✔ Lower risk of failure
  • ✔ Increased reliability
  • ✔ “Smart structures” with embedded sensing

 

ZSK TFP technology integrates functional conductor elements into the composite structure during production
ZSK TFP technology integrates functional conductor elements into the composite structure during production

 

From Fibre Preform to Finished Composite Component

ZSK TFP systems produce highly precise dry-fibre preforms that can be further processed using common resin processes.

 

Typical Process Chain

1️⃣ Digital design & FEM optimisation

 

2️⃣ Generation of fibre paths

 

3️⃣ Automated TFP production on ZSK machines

 

4️⃣ Resin infusion / RTM / pressing

 

5️⃣ Curing & trimming

 

6️⃣ Final assembly

 

ZSK Sticklösungen mit TFP - Drohnenfertigung mit Tailored Fiber Placement (TFP)
ZSK Sticklösungen mit TFP - Drohnenfertigung mit Tailored Fiber Placement (TFP)
ZSK Sticklösungen mit TFP - Drohnenfertigung mit Tailored Fiber Placement (TFP)
ZSK Sticklösungen mit TFP - Drohnenfertigung mit Tailored Fiber Placement (TFP)
ZSK Sticklösungen mit TFP - Drohnenfertigung mit Tailored Fiber Placement (TFP)
ZSK Sticklösungen mit TFP - Drohnenfertigung mit Tailored Fiber Placement (TFP)

Complete Solutions for Series Production

For customers requiring fully finished composite components, our partners such as Unwind3D offer product development, tooling, mould design and manufacture, and consolidation solutions.
This creates a seamless industrial workflow – from fibre placement to ready-to-install drone components.

 

 

Advantages of ZSK TFP Technology for UAV Production

1️⃣ Load-Path-Optimised Structures

Fibres aligned with principal load paths • Maximum stiffness-to-weight ratio • FEM-driven engineering approach

 

2️⃣ Material & Cost Efficiency

Reduced carbon fibre consumption • Minimal waste • Lower material costs

 

3️⃣ Automation & Scalability

High repeatability • Digital production workflow • Ideal for mid-volume production • Industrial-grade automation

 

4️⃣ Design Freedom

Variable wall thicknesses • Local reinforcements • Complex geometries • Integrated functions

 

5️⃣ Proven German Engineering

Industrial-grade machines • Long-term reliability • Global service network • Continuous innovation

 

Why TFP Is Particularly Valuable for Drones

Technology

Limitations

Prepreg laminates

Uniform thickness, material waste

CNC carbon plates

High scrap rate, limited optimisation

Pultrusion

No local reinforcement

AFP / ATL

High investment costs, limited flexibility

 

Tailored Fibre Placement (TFP) with ZSK

  • ✔ High structural efficiency
  • ✔ Flexible design
  • ✔ Low tooling costs
  • ✔ Shorter development cycles
  • ✔ Improved competitiveness

Suitable for:

  • Industrial drones
  • Inspection UAVs
  • Long-range platforms
  • Military UAVs
  • VTOL systems
  • High-performance racing drones

 

Economic Benefits: Performance That Delivers

 

TFP Components Improve Operational Efficiency

✅ Lower weight → longer flight time

✅ Higher stiffness → improved flight stability

✅ Reduced vibration → longer motor service life

✅ Integrated electronics → simplified assembly

 

Result

✅ Higher payload capacity

✅ Lower maintenance costs

✅ Longer service life

✅ Improved ROI

 

ZSK – Your Partner for Advanced Drone Manufacturing

ZSK is one of the world’s leading manufacturers of industrial embroidery and TFP systems.

With decades of experience in technical embroidery and composite reinforcement, ZSK supports drone manufacturers with:

 

 

From prototype development to series production – ZSK enables your path to high-performance UAV structures.

Start Your TFP Drone Project with ZSK

Would you like to:

  • Develop lightweight drone arms?
  • Integrate sensors into carbon structures?
  • Reduce weight and material costs?
  • Automate your composite manufacturing?

 

Our experts support you from concept to production.

Contact ZSK to discuss your drone application.

 
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