Epoxy resins and polyester resins are among the most important materials in the production of modern drones. They are used to create lightweight, durable, and weather-resistant structures – from arms and wings to fairings and rotating components. In this article, we explain exactly what these materials are used for, show the differences between them, and provide real examples of companies that use them.
Why are resins crucial in drones?
Drones require materials with low mass and high strength. Epoxy resins combined with carbon or glass fiber offer the best strength-to-weight ratio, which is why they are the standard in UAV designs. Polyester resins, on the other hand, are cheaper and faster to process, making them ideal for molds, fairings, and prototypes.
Applications of epoxy and polyester resins in drones
Fuselages, arms, and wings
Epoxy used in infusion or RTM technology allows for the creation of lightweight and rigid structural components. For example, Hawthorn Composites used epoxy in VARTM technology and reduced the production costs of UAV components by over 40%. Similarly, global manufacturer Hexcel supplies epoxy prepregs for most drone designs.
Delivery and defense drones
Zipline drones, developed in collaboration with Mubea Aviation, use epoxy composites manufactured using the RTM process, which increases the structure's payload capacity and durability. In the defense and security segment (e.g., DeltaQuad), carbon fiber-reinforced epoxies dominate to ensure maximum flight time.
Fairings, covers, and electronics enclosures
Components requiring radio transparency (e.g., GNSS antenna compartments or sensor covers) are often made from epoxy-based GFRP. Polyester is also used in less demanding applications, reducing costs and speeding up production. An example is the COBRA projects, which introduced composite drone fuselage covers into mass production.
Propellers and rotating components
Scientific research confirms that nano-additive-modified epoxies improve the durability and resistance of UAV propellers to UV radiation and dynamic loads. This is an important factor in the construction of racing and long-range drones.
Molds and prototypes
Polyester resins dominate this area. They are cheaper and cure faster, making them ideal for molds, fairings, and prototype skins. In many academic and low-cost UAV projects, fuselages are made from glass fiber and polyester using the contact molding method.
Epoxy or polyester – which should you choose?
- Epoxy – when low mass, high stiffness, and durability are important (arms, fuselage, wings, propellers).
- Polyester – when low cost and fast molding are key (molds, fairings, enclosures, prototypes).
Examples of companies and projects
- Hexcel – epoxy prepregs in UAV designs worldwide.
- Hawthorn Composites – significant savings thanks to epoxy used in VARTM and RTM processes.
- Zipline & Mubea Aviation – delivery drones made with CFRP/epoxy.
- WingtraOne – glass fiber (GFRP) airframe in photogrammetry drones.
- DJI – Matrice arms made of carbon fiber and epoxy.
- COBRA – mass production of composite drone fuselage covers.
Resin catalog – download now
If you are planning a drone project, it is worth viewing the full range and comparing the properties of the resins – download our 2025 epoxy and polyester resin catalog, where you will find a comparison of properties, curing temperature ranges, mechanical strength, and applications.
Summary
Epoxy resins are the best choice for load-bearing components, propellers, and structures where reliability and mass are critical. Polyester resins prove to be a fast and economical solution for molds, fairings, and prototypes. Both systems are used in practice by the world's largest UAV manufacturers – from DJI and Wingtra to Zipline and specialist companies such as Hawthorn Composites and COBRA.
How gaz-bud.pl can help you
In our store, you will find a wide selection of epoxy resins and polyester resins, as well as lamination and infusion accessories. We will advise you on choosing the right system for your UAV project – from prototype to mass production. Contact us, and we will select a solution tailored to your needs.
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