Any thoughts on the best material for the 3D printed FPV nose? TPU, PLA?
I've done some testing on several different material and frankly PLA is probably fine for the camera mount. It's cheap, easy to print and relatively strong (although somewhat brittle). If heat is a concern (like with the motor mounts) you'd want to use something that can withstand more heat than PLA. PETG, nylon, abs would be my choices for an application like that. PETG is tough but not extremely rigid, readily available and cheap. Nylon is extremely tough but is a bit pricey and difficult to print (it likes to warp). And ABS would be my last choice because it's not super easy to print (it also likes to warp) and it's not very strong. It is cheap and easy to get though.
If you're looking for extreme strength, there's carbon-fiber filled nylon (NylonX), although they suggest a larger print nozzle than what is normally used on printers so that the "micro chopped" fiber doesn't clog anything up (I'm using a .6mm nozzle without issue). I've used nylonX on some parts that needed to be extremely strong, and it is definitely strong and rigid, although I'm not sure it's worth the price. I think it was $65 for 1/2 a kilo, whereas PLA is $15/kilo. Also in the super strength category is poly-carbonate which I have some of but have not printed with yet. It is supposed to be much stronger than anything else, but hard to print because of warping. A heated build chamber significantly helps with the warping issue depending on what printer you use.
Hope this helps!
I use a Prusa i3 mk2 by the way, and I've upgraded the hotend to an e3d volcano. Amazing tool!