Fully 3D-printed drone hits 408 mph, reclaims world speed record

A fully 3D-printed quadcopter has officially reclaimed the title of world's fastest drone, reaching a verified top speed of 659 kilometers per hour (408 mph) with tailwind assistance. The achievement, verified by Guinness World Records, was accomplished by engineer and YouTuber Luke Maximo Bell and his father after more than two years of development.

The Peregreen V4 recorded a two-run average of 657 kmph under official verification, with an impressive upwind speed of 599 kmph—14 kmph faster than its predecessor. This performance surpassed the previous record of 626 kmph (389 mph) set by Australian aerospace engineer Ben Biggs with his Blackbird drone, restoring the title to the Bell family after their earlier attempt was overtaken.

Engineering Through Simulation and Prototyping

The project's success relied heavily on computational fluid dynamics (CFD) modeling and iterative flight testing. The team used the AirShaper platform to run extensive airflow simulations, which informed the design of a larger, smoother outer shell that cuts through air more efficiently while reducing drag. The final body was sanded and polished to achieve maximum surface quality.

The entire drone body was printed using a Bambu Lab H2D 3D printer with multiple materials: PETG for structural rigidity, PA6-CF (carbon fiber reinforced nylon) for strength and heat resistance, and TPU for flexible components. According to Luke, the printer's dual-nozzle system and larger build volume enabled printing the body as a single continuous piece, resulting in smoother aerodynamics and superior surface finish compared to previous iterations.

This single-piece construction eliminated seams and joints that typically create turbulence, while the multi-material approach allowed fine-tuning of mechanical flexibility and heat resistance without external fabrication services.

Motor Selection and Power Optimization

Motor testing proved critical to achieving record speeds. The team evaluated three options: the AOS Supernova, AMX 2826, and T-Motor 3120. Each was tested using strain gauges connected to an amplifier and Arduino board to measure live thrust readings during operation.

After rigorous flight testing, the T-Motor 3120 was selected for its superior reliability at high temperatures and consistent performance without failures. To maximize speed, the team increased motor windings from 800 KV to 900 KV, enabling higher RPM and faster top speeds.

Propeller design also underwent significant refinement. Initial 7×5-inch propellers were shortened to approximately 6 inches after testing revealed improved efficiency at extreme speeds. This reduction decreased drag while maintaining sufficient thrust, a crucial trade-off for breaking speed barriers.

Democratizing Aerospace Engineering

The Peregreen V4 demonstrates how accessible high-performance aerospace engineering has become. What previously required specialized facilities and equipment can now be achieved with desktop 3D printers, simulation software, and persistent testing. The project highlights the convergence of accessible manufacturing technology and computational design tools.

The Bell family's achievement extends beyond setting a record; it validates a methodology for rapid prototyping and testing that other DIY engineers can replicate. Luke has already challenged the community to surpass the new benchmark, expecting the record to be broken again soon.

This cycle of innovation—where each record inspires more accessible engineering—continues to push the boundaries of what's possible outside traditional aerospace environments. The combination of 3D printing, CFD simulation, and methodical component testing has created a new pathway for high-speed drone development that doesn't depend on institutional resources.

For builders interested in similar projects, the approach demonstrates that success comes from systematic testing, simulation-guided design, and material selection based on real-world performance data rather than specifications alone.