This work presents the design, modeling, and 3D printing of a model glider aircraft using Acrylonitrile Butadiene Styrene (ABS) filament. The primary objective was to evaluate the complete process of developing a small-scale aircraft through additive manufacturing, from theoretical design to fabrication and testing. The conceptual design was carried out using handbook methods from Daniel P. Raymer’s Aircraft Design: A Conceptual Approach, with design requirements specifying a wingspan of 1.4 m and a design speed of 7 m/s. The geometry was modeled in SolidWorks, where a structured setup allowed rapid modification of key dimensions and lead to efficient prototyping. Several printing orientations and assembly techniques were tested to assess their influence on structural robustness, print quality, and ease of assembly. The report found that printing orientation plays a decisive role: wings printed along the leading edge achieved the highest strength, while the fuselage printed on its side provided optimal integration with the wing box structure. Testing confirmed that the design and manufacturing approach enabled quick iterations, though achieving proper mass balance without going over the design weight remained challenging. Future improvements include the use of lighter materials, custom internal structure, dual-extrusion printers for optimized support removal, and standardized launching systems to enhance testing repeatability.