PLA is pretty bad compared to foam when it comes to planes, as it's very heavy and very brittle. Any semi-hard landing will break parts off, and heavy planes fly badly.
The big advantage is that you can just print the part again, which almost makes PLA worth it.
ABS would probably be better, as it's much more durable and lighter, but it's still much heavier than foam, and printing ABS isn't great.
I used single wall foaming PLA which has filament density of ~0.45 g/cm3 at 250 degree nozzle temp, about 64% lower than normal PLA. But it is even worse for impact resistance than normal PLA. Weight was the primary driver for this plane
Yep, I've used that as well, but, as you say, it's just very bad for impact resistance. I think the sweet spot between weight and durability might be ABS or something like ASA.
Yes and there is foaming ASA as well which is almost as light as foaming PLA. But I can't print ASA well on my A1 and the weight penalty was still enough that I didn't try, given the mission profile of flight time.
Did I dream or is there even foaming TPU? TPU in general seems almost indestructible to me so should be good :)
Printing ABS is much improved with the later hobbyist-level 3D printers (Qidi and Bambu etc). My Qidi Plus 4 prints ABS as easily / well as PLA. Just remember to do it in a well-ventilated space.
Sorry, I meant about the ventilation, yeah. My Bambu doesn't care what material it is, they all print perfectly, but I hate the fumes.