Tailored Fibre Placement (TFP) for UAV and drone manufacturing

High-performance carbon structures with ZSK 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 smarter than conventional composite materials.

 

Through precise, stitch-based fibre placement, ZSK embroidery machines enable the automated production of load-path-optimised structures for UAV and drone applications – from arms and frames to integrated sensor and heating systems.

 

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 perfectly.

 

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 addresses these challenges

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

 

Result: Up to 25% weight reduction at the same or higher stiffness.

 

 

Typical drone components made with TFP

Drone arms and booms

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

 

Motor and propeller interfaces

  • Circular fibre layouts around fastener points
  • Local fatigue reinforcement
  • High fatigue strength at elevated rotational speeds

Central frame and chassis

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

 

Structural housings

  • Battery housings
  • Payload carriers and camera mounts
  • Sensor housings

 

Advantage: Fewer individual parts with higher mechanical efficiency.

 

 

Integrated functional conductor structures: heating, sensors and 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 manufacturing.

 

Can be integrated:

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

 

Your benefits

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

 

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

 

 

From fibre preform to finished composite component

ZSK TFP systems produce high-precision dry-fibre preforms that are further processed using common resin methods.

 

Typical process chain

Complete solutions for series production

For customers requiring fully finished composite components, our partners such as Unwind3D provide product development, tooling, mould construction and composite consolidation solutions.

 

This creates a seamless industrial production workflow – from automated fibre placement to the ready-to-install drone component.

UNWIND3D specialised technology company for advanced fibre composite engineering and UAV structures

 

 

Technical embroidery systems for series production

CMCW 0200 ZSK Tailored Fibre Placement system for manufacturing large carbon fibre composite structures

 

CMCW 0200

ZSK technical embroidery system for Tailored Fibre Placement with a large embroidery field of 2,900 mm x 2,100 mm or two production areas of 2,100 mm x 2,100 mm each.

CMCW 0600 ZSK TFP manufacturing system with six production areas for carbon fibre preforms

 

CMCW 0600

ZSK technical embroidery system with six production areas of 600 mm x 600 mm each and optional active fibre feeding for automated TFP production.

CZCW 0800 ZSK industrial TFP embroidery system for scalable composite manufacturing

 

CZCW 0800

ZSK technical embroidery system with eight production areas of 900 mm x 1,400 mm each or four production areas of 1,800 mm x 1,400 mm each.

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)

Advantages of ZSK TFP technology for UAV production

1️⃣ Load-path-optimised structures

Fibres aligned along the main stress paths • Maximum stiffness-to-weight ratio • FEM-based engineering approach

 

2️⃣ Material and cost efficiency

Reduced carbon fibre consumption • Minimal waste • Lower material costs

 

3️⃣ Automation and scalability

High repeatability • Digital production workflow • Ideal for medium production volumes • 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 drone manufacturing

The following table compares conventional production methods and their limitations.

 

Technology

Limitations

Prepreg laminates

Uniform thickness, material waste

CNC carbon plates

High material waste, limited optimisation

Pultrusion

No local reinforcement

AFP / ATL

High investment costs, limited flexibility

 

 

Economic benefits: performance that pays off

TFP components increase operational efficiency

❕  Lower weight → longer flight time

❕  Higher stiffness → improved flight stability

❕  Reduced vibration → longer motor lifetime

❕  Integrated electronics → simplified assembly

The result

✅ Higher payload capacity

✅ Lower maintenance costs

✅ Longer service life

✅ Improved ROI

 

 

ZSK – your partner for modern drone manufacturing

ZSK STICKMASCHINEN 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:

 

A comprehensive process offering

  • ✔ Machine technology
  • ✔ Application engineering
  • ✔ Process development
  • ✔ Training and support
  • ✔ Global service network

Extensive expertise in Tailored Fibre Placement (TFP)

  • ✔ High structural efficiency
  • ✔ Flexible design
  • ✔ Low tooling costs
  • ✔ Faster development cycles
  • ✔ Competitive advantage

ZSK technical embroidery systems and the additive manufacturing process TFP – Tailored Fibre Placement are ideal for the production of:

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

 

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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Tailored Fibre Placement (TFP) – Technology Overview

Tailored Fibre Placement (TFP) is an advanced composite manufacturing technology in which carbon fibres are placed precisely along load paths using industrial embroidery machines.

This stitch-based process enables the production of lightweight, high-performance composite structures with variable-angle fibre orientation.

Compared with conventional laminate manufacturing, TFP allows higher structural efficiency, reduced material consumption and greater design flexibility.

The technology is widely used in aerospace, UAV manufacturing and advanced lightweight engineering.