Creating 3D Printed Aircraft Liveries Without 3D Modeling (Tutorial)

Thanks to MakerWorld, we can share our favorite 3D printed aircraft models with aviation enthusiasts worldwide.

In the comments section of our released models like the A320 and A330, we often see friends wishing for versions featuring their favorite airline liveries. Our time and resources are limited, so we cannot fulfill every personalized request. Therefore, we have been thinking about how to provide a method for everyone to create different airline liveries without using 3D modeling software.

Combining our experience with Bambu Studio, we have gradually developed a method for creating custom liveries and are sharing it now, hoping it will help friends who want to make their own liveries.

For this DIY livery approach, the basic skill requirement is: familiarity with 2D vector graphic design software like Adobe Illustrator or Affinity Designer. Simple vector graphic editing skills suffice. In the following tutorial, we will use Adobe Illustrator as an example.

​I. Determine the Livery Creation Method: 3D Printing or Custom Stickers?​

Aircraft fuselage livery elements come in many forms. Aside from complex artistic liveries, the livery features of most common commercial airliners typically include the following 5 types of elements:

1. ​​Base Color for Fuselage and Engine Nacelles:​​ Most airlines choose white paint, while some select other colors, like ITA Airways’ blue paint.
2. ​​Large Area Decorative Colors or Colored Lines:​​ These embody the airline’s characteristics, like Lufthansa’s tail color variation or KLM’s blue + gray combination.
3. ​​Airline Name, LOGO, and Other Identifiable Elements:​​ These identifiers are usually large and offer good recognition.
4. ​​Other Small Additional Symbols:​​ For example, aircraft registration numbers, aircraft type markings, flags, airline alliance LOGOs, or aircraft nicknames. These identifiers are relatively small and are very difficult to represent well with 3D printing.
5. ​Windshield, Cabin Doors, Cargo Doors, etc.:​​ These elements are represented in our 3D models through engraved lines on the fuselage. For a more detailed effect, stickers can also be used.

Large-area colors in categories 1-3 can be achieved through multi-color printing. However, the small elements on the fuselage in categories 4-5 (like registration numbers, flags, etc.), due to their small size, usually produce poor results with 3D printing. Using an ordinary 2D printer to print stickers yields a much better effect.

Therefore, considering the characteristics of 3D printing and the different types of aircraft livery elements mentioned above, for the livery you choose, we recommend combining the following two methods:

• ​​Method One: Printing Stickers:​​ For the small-sized elements on the fuselage (category 4-5), or elements difficult for 3D printing like flat LOGOs or LOGOs with gradient colors (category 3), using printed stickers solves the problem of 3D printing precision. If you have a 0.2mm nozzle, you could also consider printing colored thin sheets with the 3D printer and attaching them to the fuselage with fast-drying glue as an alternative to stickers.
• ​​Method Two: Multi-Color 3D Printing:​​ Large areas of color (categories 1-3) are more suitably achieved with multi-color printing. This is especially true for curved areas with complex shapes like the nose, tail, and belly, where it’s very difficult for stickers to lie flat and fit well.

By combining these two methods, most custom livery requirements can be addressed. Below, using our released A320neo model as an example and provided PDF template files, we will detail both methods.

​II. Method One: Custom Stickers​​

We provide a sample file (PDF format) that is scaled to match our A320neo model released on MakerWorld. Using this PDF drawing, you can directly design the fuselage stickers.

The PDF file contains drawings from various angles. The “Projection diagram” layer includes the fuselage, wings, empennage, winglets, engines, etc., as well as top and bottom views. In the “Common Elements” layer, we provide graphics for the commonly used gray areas on top of the wings and evacuation signs.

The PDF file contains two example sticker livery layers: China Eastern Airlines and Transavia Airlines. After designing your livery, copy its content to a blank file for sticker printing.

Here are some tips for creating sticker files:

1. ​​Downloading Airline LOGOs:​​ Search online using keywords like “[Airline Name] LOGO SVG”. Vector SVG files can be easily found online; practically all airline LOGOs are available. Websites we commonly use include: [https://seeklogo.com], [https://latestlogo.com/]
2. ​​Pay Attention to Curved and Slanted Surfaces of Fuselage and Wings:​​ Observe how the livery relates to the curved features of the fuselage. Most airline LOGOs are placed according to their original proportions conforming to the fuselage curves, but sometimes the LOGO or colored lines need slight perspective distortion.
3. ​​Cut Out Windows:​​ Ensure that any parts of the LOGO graphic overlapping the aircraft windows are cut out (hollowed) in your sticker design to avoid covering the printed aircraft windows. When manually cutting stickers after printing, meticulous handwork is required around areas like the windows to ensure a good result.
4. ​​Choosing Sticker Material:​​ Common laser or inkjet printable sticker papers include: water slide transfer decals, paper sticker sheets, PP synthetic paper sticker sheets, and transparent sticker sheets. Water slide transfers require a complex production process and some experience. We tested paper sticker sheets, PP synthetic paper sticker sheets, and transparent sticker sheets. In terms of results, the PP synthetic paper sticker sheets we used gave the best effect.
5. ​​Using Bambu Lab’s “Print Then Cut” Function for Precise Cutting:​​ If you have a Bambu Lab H2D printer, you can use the “Print Then Cut” function in Bambu Suite to create stickers ready for direct use. We also provide Bambu Suite files for the two example liveries mentioned above. They can be found at the links: [China Eastern Airlines Livery Stickers], [Transavia Airlines Livery Stickers]. These files are for your reference when making your own stickers. When using Bambu Suite’s “Print Then Cut” function, we noted that the maximum sticker size it can produce is approximately “261.6mm X 170.6mm”. For large-scale stickers, they may need to be split into two segments to fit within this size limit.

III. Method Two: Flexible Use of Multi-Color Printing​​

To help friends without 3D modeling skills, we’ve developed a simple method. The basic principle is to use Bambu Studio’s “Modifier” function to differentiate areas that require different filament colors.

This method utilizes two key tools:

1. Using plane design software to draw the shapes for the different color sections and exporting them as SVG format files that Bambu Studio can import.
2. Using the ​​Alignment Blocks​​ provided in our 3MF file to align the modifiers generated from the SVG files.

Here, using the example of creating the SAS A320neo livery with registration SE-ROL, we will explain how to create the color-separation SVG files and how to use the Modifier function.

We analyzed this livery and, considering the element categories and characteristics of 3D printing, decided on combining the following two implementation methods:

• ​​Method One: Use 2D printed stickers​​ for: Fuselage registration number, nose landing gear registration text, colored band markings on the fuselage, Star Alliance logo, and outlines for doors and evacuation hatches.
• ​​Method Two: Use multi-color printing​​ for: The blue section extending down from the vertical stabilizer on the tail, the SAS text LOGO on the tail, the SAS text LOGO on the forward fuselage, the blue parts of the winglets, and the blue section at the front of the engines.

The creation process for Method One refers to the sticker examples mentioned earlier and won’t be repeated. Below, we focus on implementing Method Two.

Before starting, we strongly recommend downloading and opening these two files in Bambu Studio: the Blank Fuselage 3MF file and the SAS Livery Example file. Use them as references in the following creation process.

First, familiarize yourself with the positioning graphic blocks in the 3MF and template files used for SVG creation.

To facilitate modification and positioning during the livery creation process, we have split the horizontal stabilizer and vertical stabilizer from the tail assembly in the 3MF file into independent ​​Parts​​. We also added ​​Alignment Blocks​​ (5mm-sided yellow semi-transparent cubes set as “Modifier” type) to the fuselage and vertical stabilizer parts.

In the PDF file, turn on the “AMS_Alignment Blocks” layer to display the drawing reference lines and yellow ​​Alignment Blocks​​. These blocks correspond one-to-one with those in the 3MF file and are used for subsequent drawing and positioning in Bambu Studio.

Step 1: Draw color blocks for areas with color changes.​​
Select suitable reference photos. Draw the color blocks for the areas that change color. It’s okay if the blocks slightly extend beyond the fuselage at this stage; it won’t affect later steps.

​​Step 2: Split the color blocks and align them with the Alignment Blocks.​​
Using your design software’s editing functions, split the large color block based on the positions of the fuselage parts. Simultaneously, extend a part of the graphic onto the corresponding ​​Alignment Block​​. Pay attention to the positions indicated by the red arrows in the image below: the width and boundaries where the graphic meets the Alignment Block must be precise to ensure accurate positioning later.

(Image Caption): Splitting the fuselage color blocks and aligning with the Alignment Blocks.

After drawing, export each color block as a separate SVG file. Below, using the tail section as an example, we demonstrate the subsequent process.

(Image Caption): The exported SVG file for the tail coloring.

​Check the exported SVG files individually to ensure they are intact.​​

(Image Caption): Checking the exported SVG file.

​​Step 3: Import the SVG file onto the corresponding plate in Bambu Studio.​​
On the ​​plate​​ where the tail part resides, right-click in a blank area, select “Add Primitive” → “SVG”, and import the SVG file for modifying the tail color.

(Image Caption): Adding the SVG as a entity.

​​Step 4: Scale and rotate the imported SVG primitive.​​
The size of the imported SVG entity will likely change. Therefore, open your design software and note down the width and height dimensions of the original graphic you just imported (in this file, it’s “125.831mm X 52.668mm”). Return to Bambu Studio and modify the SVG primitive’s scale accordingly.

(Image Caption): Scaling the imported SVG primitive.

When scaling the SVG entity, do it in two steps:

• First, modify the X/Y dimensions: Ensure “Uniform Scale” is checked to maintain proportions. Enter the target width or height based on your recorded dimensions.
• Second, modify the Z dimension (part thickness): Uncheck “Uniform Scale”. Set the Z dimension value based on the size of the part you want to color. The Z value must be large enough to cover the entire target part. In this tail example, the part diameter is about 50mm, so set Z to at least 50mm (we used 60mm).
  

To facilitate positioning in the next step, rotate the SVG entity roughly according to its assembly orientation (in this example, rotate it 90 degrees).

(Image Caption): Rotating the SVG entity.

​​Step 5: Combine the SVG entity with the target part and set it as a “Modifier”.​​
Hold down the “Ctrl” key, select both the SVG entity and the tail ​​Part​​, then perform the “​​Merge​​” operation.

(Image Caption): Merging the SVG entity with the fuselage tail part.

After merging, select the imported SVG entity within the merged part in the “Objects” menu, and change its type to “​​Modifier​​”.

(Image Caption): Changing the merged SVG entity to a “Modifier”.

​​Step 6: Precisely position the SVG Modifier using an Alignment Block.​​
This crucial step uses the ​​Alignment Block​​ provided in the 3MF file. Select the merged part (containing the SVG Modifier), then click the “​​Assemble​​” tool icon. Use the “Face and Face Assembly” alignment command.

(Image Caption): Using the “Assemble” tool to position the modifier.

Within this command:
a. ** Select the inner face of the ​​Alignment Block​**​ (yellow cube) in the 3MF file as “Face 1” (the fixed face).

(Image Caption): Selecting the Alignment Block surface as Face1.

b. Select the corresponding face on the SVG Modifier as “Face 2” (the face to be moved).

(Image Caption): Selecting the modifier surface as Face2.

c. Click “Center Coincidence”. This moves the ​​SVG Modifier​​ to the precise location aligned with the ​​Alignment Block​​.

(Image Caption): Using “Center Coincidence” to align modifier and Alignment Block.

Now, check if the position matches your designed location.

(Image Caption): Verifying the modifier position matches the design.

​​Step 7: Assign the SVG Modifier’s material and slice to confirm.​​
Change the ​​Filament​​ assigned to the “SVG Modifier” to the blue ​Filament​​. Notice that a multi-color ​​Prime Tower​​ appears on the ​plate​.

(Image Caption): Assigning blue filament to the modifier.

Final Step: Slice Plate to confirm the multi-color printing modification is accurate.

(Image Caption): Slicing to check the multi-color printing effect.

At this point, the multi-color printing modification for a single part is complete. Repeat the above steps for other parts requiring multi-color elements.

Here are some tips for Multi-Color File Creation:​​

1. ​​The Correct & Most Efficient Production Method:​​ Multi-color printing is suitable for complex curved surfaces where stickers are difficult to apply. The SAS LOGO on the fuselage and tail in the example above would likely be more suitable for stickers; we used multi-color printing here purely for demonstration. Since Bambu Lab released the H2D printer, multi-color printing has become much more efficient. Airline fuselage liveries typically use only two main colors, making them particularly ideal for H2D’s dual-nozzle printing.

2. ​​Positioning Mid-Fuselage Color Blocks:​​ For color blocks located in the middle of the fuselage away from any Alignment Block (e.g., the forward SAS LOGO), design the SVG Modifier to extend around the fuselage part and include a connection element within Bambu Studio.
   

• (Image Caption): Designing an SVG modifier around the fuselage part.
• The sections indicated by the red arrows will be below the ​​Printing Platform​​ plane during printing and won’t affect filament selection for the fuselage itself.
• If elements (like the 2nd ‘A’ and 3rd ‘S’ letters in the SAS LOGO) cannot connect directly to an Alignment Block, export them together with the first letter. When generating the SVG entity in Bambu Studio, add a connecting rectangular block. Use the “Mesh Boolean” function to merge all the SVG letters and the connector block into a single object. Ensure the connecting rectangular block avoids the fuselage solid model to prevent interfering with its filament color.
  
  (Image Caption): Merging letters using a connector block and Mesh Boolean.

3. ​​Accounting for Different Left/Right Sides & Modifier Thickness:​​ For different color blocks on the left and right sides of the fuselage (like the SAS LOGO example where the lettering differs), after aligning the SVG Modifier to the Alignment Block, it needs to be moved laterally by an appropriate distance. Refer to our provided example file for implementation details.
   

• (Image Caption): Modifier positioned differently for left and right side of fuselage.

4. ​​Using Supports for Small Overhangs:​​ If small ​​Overhangs​​ are detected after initial slicing, enable ​​Support​​ generation. For example, small overhangs occur at the arrowed SAS LOGO positions. Without ​​Support​​, printing might fail there.
   

• (Image Caption): Overhang requiring support generation.*

5. ​​Optimize Filament Changes:​​ Arrange modified fuselage and vertical stabilizer parts across one or more ​plates​​ based on the color combinations and required ​​filament changes​​. This minimizes material swaps and achieves the most efficient 3D printing workflow.

By flexibly using the various functions shown in these examples, you can achieve multi-color printing for different fuselage colors. Of course, during actual production, other 3D printing parameters like layer height, infill density, supports, and print speeds should also be adjusted specifically to achieve the best results.

Welcome to ask questions if any part of the tutorial is unclear; we will do our best to answer them.

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