Showing posts with label aircraft. Show all posts
Showing posts with label aircraft. Show all posts

3D Printed Small Internal Combustion Engine from Romania

Researchers from Romania 3d printed a small working two-stroke engine on a professional metal 3d printer.

Project description:
Romanian Valentin Stamate, a researcher at the Transilvania University in Brasov, presented a 3D printed two-stroke airplane engine prototype. It cost some EUR 20,000 to manufacture and the expense was undertaken by the Brasov University.
The engine is a 10 cubic centimeters one, with 10,000 rotations per minute. Most of the engine parts were produced by SLM and SLS-type 3D printers out of steel, aluminum, and steel and bronze powders. The only parts that were not 3D printed were the propeller, which is made of wood, the cone and its fastening system, the supporting bearings, the screws, the nuts and the spark. The engine is fueled by a mix of methanol and oil.

Now, I know what you are thinking: interesting project but 20 thousand euro is a lot of money for a small engine. Any you are right.
The first thing that came to my mind was my lawn mover broke a few days ago, and since I live in Croatia the replacement part was hard to find and too expensive for my taste. There are MANY small engines in the world and with right investment and economics of scale, this is a very large market. Just the replacement part market is huge with thousands of different engine models with hundreds of parts each.

THIS WORLD NEEDS CHEAPER and OPEN SOURCED 3D PRINTABLE SMALL ENGINES!!!
Now go and make it happen.






















Source:

https://www.romania-insider.com/romanian-researcher-presents-3d-printed-plane-engine-prototype/

Tom Stanton 3D Prints his RC Flying Wing

Tom Stanton show us his trials and tribulations to get a 3d printed flying wing RC aircraft in the air. Interesting watch if you are into this hobby.

Here is his first video where he goes into design and basic parts printing:



Here is the fully 3d printed flying wing being developed and tested:



The aircraft was printed from clear PLA filament with a 0,4mm nozzle at 220 degree Celsius to maximise the layer strength. Weight of the aircraft was 730g.

Tom's Thingiverse page:

http://www.thingiverse.com/StantonFrames/about

Low-cost Easy 3D Printed RC Flying Wing

Samm Sheperd demonstrates how easy and cheap it is to develop and 3d print a flying wing pod that houses first person camera, transmitter, controls, motor, batter, drive shaft and propeller for a RC plane.

Her is a video of his design flying:



Here is a Thingiverse with all the files you need to print it yourself:

http://www.thingiverse.com/thing:1412963



DIY 3D Printed Electric Ducted Fan Engine with Thrust Reversal

Harcoreta made this incredible 3d printed jet engine for RC applications modeled on GE GEnx-1B. It is very detailed Electric Ducted Fan (EDF) motor with NTM 1400kv 35mm brushless motor located inside the core which is cooled by a small impeller. It even features working thrust reversal system.
It was printed on Reprap Prusa I3 at 0.1mm layer height and then smoothed by using an acrylic thinner.

The files of it are not available ... yet





Details of thrust reversal mechanism:




Technical specifications of the model motor:
  • 100mm diameter 18 blade main fan scale looking. 24 outlet guide vanes.
  • 34 mm diamenter 18 blade internal turbine, installed on the back shaft of the motor, It's designed only for cooling the motor. Over this section there are a sequence of stator vanes and supports to optimize the airflow. This internal airflow could produce thrust but in any case it'll be a few grams.
  • Scale looking nacelle, the major differences are the simplified engine pylon and the minor reduction on the exhaust area, about 95% fsa
  • Thrust reverser, complete system with translating cowl, blocker doors and cascades. The most complicated parts that must work.
  • NTM 1400kv 35mm motor. Thrust target > 0.5Kg with 3S or 4S maximum.

Project thread with more information:

http://www.rcgroups.com/forums/showthread.php?t=2390401



SLA 3D Printed Working DIY RC Micro Drone "Air-Form 1"

Thingiverse user "niklasm" designed and 3d printed a fully working micro RC drone from tough resin on a Form 1.
























Technical specifications:
  • battery: 150mAh
  • thrust: 54g
  • weight: 60g
  • wingspan: 58cm
  • dihedral: 15deg
  • flight time: 11min
Non-Printed Parts:
  • specktrum ar6410
  • 150mAh battery
  • laTrax motor
  • laTrax bearings
  • laTrax gear/propshaft
  • laTrax prop
  • 3/32in X 7/32in X 3ft rectangular carbon rod
  • 3/16in carbon tube
  • 7/64 carbon rod
  • 3ft X 3in X 3/32 balsa board
  • 1/32in music wire
  • superglue

All the files to make it and instructions can be found at:

http://www.thingiverse.com/thing:1051655

Red Swan Large Wingspan Fully 3D Printed RC Flying Wing

Here is a largest fully 3d printed and flying RC model airplane. It has no reinforcements and it reaches almost 2 meters in wingspan. Really pushing the limits of possible there.

Technical Specifications
  • wing span: 1950 mm
  • wing chord: 336 mm
  • aerodynamic center: 80.2 mm
  • aerodynamic center 8% stability: 61.4 mm
  • wing profil: Clark YS
  • wing overall weight: 1520 g
  • wing area: 65,52 dm²
  • fuselage overall weight 730 g
  • wing loading: 34,3 g/dm²
  • longitudinal stability (Thies) STFs: 65,0
  • motor: Robbe Roxxy BL Outrunner 2834-08
  • propeller: Aeronaut CAM 10 x 6”
  • static thrust: 1100 g (3S Lipo)
  • print time wing: 120 h
  • print time fuselage: 35 h
  • used PLA: 1.8 kg

Here are take-off, flight and lending in a video:





You can find all the files and instructions at Thingiverse:

http://www.thingiverse.com/thing:453090



3D Printable Tetrahedral Box Kites: Triforce and OpenKite


Triforce Kite


Sergej Bekauv designed and printed this DIY tetrahedral kite named the "Triforce Kite". 

It is a fully functional flying folding kite with 3d printed structures (27 trusses) and lift surfaces made from Mylar (spaceblanket or emergency blanket type of material). 
































The design and build process is well photo-documented at:




Here are some videos of it:




... here it transforms:




All the files for it and instructions can be found at:

http://www.thingiverse.com/thing:952737


This type of kite was invented by Alexander Graham Bell (yes, the telephone guy) and hi did some amazing work with them making enormous versions:

http://www.carnetdevol.org/Bell/kite.html

https://en.wikisource.org/wiki/Popular_Science_Monthly/Volume_64/December_1903/The_Tetrahedral_Kites_of_Dr_Alexander_Graham_Bell


Open Kite


Open Kite is an open source tetrahedral kite project developed by Sehun Oh. Here is his description of the project:
The project brief was about designing a product for play. While I was trying to explore the world of play, I was fascinated by Little Shining Man (Heather & Ivan Morrison, 2011), a huge cubic kite which consists of hundreds of tetrahedral cells, and I decided to explore this intriguing architectural structure.
During the process, I designed 3D printable components for easier and faster kite building and I also found out a way to make the structure collapsible, so that it can be flatten when not in use. Little Shining Man is basically a flying sculpture, so it can be transported on a truck and displayed or stored at a gallery.
Whereas when people build large kites with open kite components, it is collapsible for easier transport and storage. Consequently, this tetrahedral kite becomes a more accessible 'product'. I am also planing to publicise the kite component data for 3d printing as an open source project so that people freely download and make their own tetrahedral structures.

OpenKite video:





Full build instructions and files can be found at:

http://www.sehunoh.com/openkite.html



Laser metal deposition five axis 3d printing for aerospace appliances by Merlin Project

Laser metal deposition (LMD) is DMLS process that is the future of aerospace industry. Since European Union is a manufacturing powerhouse it is investing in many R&D projects like Merlin.
Ever major technological power is in the race to rule the industry and advance in digital manufacturing age.

From project description:
A 5 axis laser metal deposition manufacturing method is being developed by TWI for an EU-funded project which is demonstrating drastic time reduction in the manufacture of aero engine casings. 
In LMD, a weld track is formed using metal powder as a filler material which is fed through a coaxial nozzle, to a melt pool created by a focused high-power laser beam.
By traversing both the nozzle and laser, a new material layer develops with precise accuracy and user-defined properties. The application of multi-layering techniques allows 3D structures to be created.
To find out more please visit the project website: http://www.merlin-project.eu/ or go to TWI's website:http://www.twi-global.com/news-events...

Here is a video of the process. It took seven and half hours to print this thin walled casing prototype for jet engine test beds.





Here is a list of LMD technical advantages and disadvantages:

Advantages of LMD:
  • Metallurgical bond (not mechanical, thermal spray)
  • Wide variety of available powders 
  • Very low dilution is possible 
  • Relatively high deposition rates 
  • Process is highly repeatable 
  • Low impact on base material compared to similar processes (HAZ) 
  • Superior metallurgy compared to similar processes 
  • Virtually unlimited build height 
  • Very flexible tool path compared to wire applications 
Disadvantages of LMD:
  • High capital equipment costs
  • Powder cost is typically higher than wire
  • Capture ratio of additive material < 100% (based on process parameters)
  • Cannot control the process manually – CNC is required 
  • Experienced, specialized staff required (e.g. laser safety engineer, skilled operators)
LMD laser toolhead schematics:



BAE Systems wants to have drones onboard 3d printing drones by 2040





BAE Systems is major military and aerospace technology company and they have presented some future concepts.

Scientists and engineers at BAE Systems have lifted the lid on some futuristic technologies that could be incorporated in military and civil aircraft of 2040 or even earlier.
Smaller unmanned aircraft -- or UAVs -- are created by super high-tech on-board 3D printers, via Additive Layer Manufacturing and robotic assembly techniques. The 3D printers respond to data fed to them by a remote control room where a human commander decides what should be produced.
The UAVs are best suited to each scenario -- be it a group of wide-winged aircraft for protracted or enduring surveillance -- or rotary-winged UAVs to rescue single civilians or soldiers from dangerous situations. After use the UAVs could render themselves useless through dissolving circuit boards or they might safely land in a recoverable position if re-use was required.
This creates the ultimate adaptable taskforce, with a lead aircraft able to enter any unknown scenario and quickly manufacture an effective toolset for any task.

Now, let's think about this:
  1. They want to do it by 2040. I am firm believer in technology, but this is going to require some STAR TREK technology guys.
  2.  If you don't develop micro fusion reactors and energy-matter conversion tech, this thing will have to carry a LOT of wight in machinery and mass for 3d printing. 
  3. Even if some similar but less developed technology is implemented, why would anyone send ultra high tech extremely expensive craft to rescue people in natural disasters when HELICOPTERS are well developed and widely used. 
  4. I also have slight suspicion that someone will want to 3d print bombs on-board of military aircraft. Still, all limitations remain. Why send something very expensive and heavy when you have proven delivery methods? Maybe some tactician is thinking of highly customized munition for very demanding missions with uncertain parameters for high-value targets. 
  5. To conclude: maybe someone should develop 3d printed guided sandwiches so we can feed all the hungry with high precision. Make food, not bombs. PEACE! 

BAE Systems page with more advanced technology future concepts like transforming drones, self-healing drones and other:

http://www.baesystems.com/enhancedarticle/BAES_168290/aircraft-technologies-of-the-future




























UPDATE:

Only two weeks from this article there is a confirmation that US military is actually working on 3d printed warheads:

http://diy3dprinting.blogspot.com/2014/07/us-military-will-3d-print-warheads-and.html

Fully functional AirDog drone prototype developed with 3d printing




AirDog is innovative quadcopter drone that will follow you automatically and record video of your activity guided with electronic bracelet "leash" or smartphone app. The fully functional prototype is 3d printed in ULTEM 9085 production grade thermoplastics.

Currently it has several flight patterns that can be expanded in future:
  1. Auto-follow. Will work with almost any sports. In this mode AirDog will follow you repeating exactly your movement trajectory while maintaining its position in preset distance and altitude from you. It will follow you at speeds up to 40 mph.
  2. Relative position follow. In this mode AirDog will maintain constant offset relative to magnetic north from the rider. For example, you can set it to keep a 10 meter distance at 4 meters high to the east from your position. Even when you change your direction, the AirDog will stay at the same preset angle from you. We suggest this mode for straight line wakeboard cable parks, surfing, and some other sports.
  3. Follow track. This is the safest way to operate AirDog. Simply go for one lap with AirLeash and it will record your track. Then adjust AirDogs trajectory to your liking in smartphone app. AirDog will repeatedly fly over the exact set trajectory and the camera will be continually adjusted to aim at the rider.This is the most creative mode where you can become a true director of your movie. Adjust AirDog's trajectory to avoid obstacles like buildings or trees. You can even make it to shoot you from different angle on different spots/kickers in the track. It might sound complicated, but its a simple few tap process in AirDog smartphone app.
  4. Hover and Aim. The Hover and Aim setting allows AirDog to stay in one position above the ground, but constantly directing the camera at the AirLeash. This setting is perfect for tight places such as smaller skateparks, narrow forest trails, or for activities such as bungee jumping or base jumping, where clearance from equipment is important.
  5. Circle. In this setting, AirDog makes circular rotations on a set radius and altitude, keeping the camera aimed at the AirLeash. This for slow speed or static shots to show impressive view around you.
  6. Look down. The most simple mode but can produce very stunning results. Simply "walk" your AirDog above a ramp or kicker where you are about to throw some epic tricks and with push of a button it will freeze its position and aim camera straight down. Now make sure you don't go too high.
  7. When it goes into production it will be produced with injection molding and it is clearly indicated on the timeline.

It was developed with Stratasys:

From Stratasys blog post:
The working prototype, currently flying in demonstrations over the United States, was produced using 3D printing technologies from Stratasys, with guidance from Stratasys’ Latvian partner, Baltic3D, and Polish reseller Bibus Menos.
“As the world’s first auto-follow action sports drone, AirDog not only grants end-users their own affordable and personal aerial video crew, but goes one step further in providing thrilling footage from distances and angles previously inaccessible to such consumers,” explained Edgars Rozentals, Co-founder and CEO of Helico Aerospace Industries.
A production-grade thermoplastic (ULTEM 9085), popular in the aerospace industry for its high strength-to-weight ratio, was used to create the AirDog quadcopter. “We were particularly impressed by how far we could push the boundaries of the ULTEM material,” said Rozentals. “The material’s functional stability enabled us to 3D print very thin walls that further reduced AirDog’s overall weight.
For the AirLeash, Helico chose to use rubber-like as well as rigid materials in a single prototype, relying on Stratasys’ PolyJet 3D printing technology, which allows for the incorporation of multiple materials in a single go.
“I’m not sure how we would have arrived at the stage of having a functional part, were it not for Stratasys 3D printing technology. I founded the company two years ago and we’re a staff of three, so for start-ups like Helico, this technology isn’t just a game-changer, but the ticket to the game itself,” ventured Rozentals.

AirDog Kickstarter:

https://www.kickstarter.com/projects/airdog/airdog-worlds-first-auto-follow-action-sports-dron

Source blog post from Stratasys:

http://blog.stratasys.com/2014/06/25/3d-printed-sports-drone-airdog/























Airbus is strongly going into 3d printing parts for aerospace applications




Big USA players like Lockheed Martin, Boeing and GE are already heavily into additive manufacturing, and Chinese are already printing big parts of jet fighters. European main aircraft producer Airbus is also now promoting themselves and their technology 3d printing advancements.  
Airbus is at the start of an innovation revolution using 3D printing technology. 3D plastic parts are already flying on a commercial A310 and an A350 XWB test aircraft. Metal parts for wing slats, a section of the tail wing and door hinges have also been made with 3D printing. In the coming years the technology will allow manufacturing costs to fall while lighter parts will mean less fuel burn for airlines.





















First successful flight video of Nomad fully 3d printed UAV




This is the third attempt and it was a good one. The Nomad modular 3d printed UAV is now airborne which is a great step forward for the project and DIY drone community!
Since the Nomad is scalable and modular, bigger versions with more interesting payloads could apper in the future.

Thnx Goig3D for sharing your work!




























Nomad modular and scalable 3d printable DIY drone























Nomad is project in development of modular 3d printable aircraft measuring one meter in wingspan powered by electric motor. Future versions will be up to 50% larger and able to carry a GoPro camera in their nose. 

Nomad is a project by CaptainObvious   

From project description:
This is the Nomad, a new design I'm working on for a travel UAV/FPV airplane. This version has a wingspan of almost one meter, so it's relatively small. After I've completed and test flown I plan to make a 30/50% larger version to carry a GoPro camera in the nose for aerial photography.
The airplane is meant to be modular, the nose and tail sections are joined to the center section with nylon screws, the wings and stabilizers are detachable and even the wing panels can be kept separate to simplify repairs and testing new design ideas.
  • The wing sections are meant to be printed in a "Spiral Vase" mode, the internal spars and/or printing settings should be adjusted so that the printing head makes the spars by moving in from the bottom of the wing until touching the inner surface of the top of the wing, so there is only one seam at the bottom.
  • I have carefully modeled the fuselage parts so that most of them will print as a two perimeter shell using a 0.4mm nozzle, except where more thickness is needed.
  • The wings need two carbon fiber tubes, 8 and 3 mm diameter, the stabilizer also uses a 3mm carbon fiber tube spar.
  • The plane will use one brushless motor mounted on the tail with a 6" propeller.
  • Things left to do: flaperons, rib between the straight wing panels and the tapered external panel, optional nose wheel, camera turret and internal brackets and supports for servos and electronics.

All files are available at: http://www.thingiverse.com/thing:272478

For more 3d printed drones take a look at:

http://diy3dprinting.blogspot.com/search/label/drone

Fully 3d printed drone by University of Sheffield AMRC and Boeing




Test flight of a prototype unmanned aerial vehicle (UAV), designed and built using fused deposition modelling by the Design & Prototyping Group at the University of Sheffield AMRC with Boeing.
The drones airframe is printed in ABS plastic.

Check out other 3d printed drones.


















Source:

https://www.youtube.com/user/AMRCsheffield?feature=watch

Update:

Now you can read all about this drone project in PDF paper released by the team:

http://www.namtec.co.uk/userfiles/files/Powered_CASESTUDY.pdf


The design is updated to be more 3d printeble on FDM machines, but the parts of the wings are carbon fiber.

There is a new video:




3D Printed PrototypeTechnology Evaluation and Research Aircraft (PTERA) fully operational arial drone

Solid Concepts teams up with Area-I and creates the world's smallest jumbo jet (737) to test high-risk circulation control systems, conformal fuel tank concepts and other advanced aerospace concepts with SLS 3D printed parts.
So, basically, full sized drones are almost fully 3d printable now. Skynet could use this technology to exterminate humanity ...

Rolls Royce is getting into 3d printing of jet engines (or how the competition is growing in aerospace additive manufacturing industry)

GE is getting heavily into 3d printing, so it is unavoidable that other big companies such as Rolls Royce will have to get in it also in order to remain competitive.  It will be interesting to how this industrial manufacturing technology will develop and what will it mean for technological development and for the labor force.


From i.materialise article:
"The Merlin Project is a 7,120,000 EUR research project that will be conducted by Rolls Royce in conjunction with other aircraft engine manufacturers. The aim of the project is to over the course of three years explore the use of 3D printing to make aircraft engines in order to reduce their environmental impact. The project aims to use 3D printing “to allow environmental benefits including near 100% material utilization current buy to fly ratios result in massive amounts of waste, no toxic chemical usage and no tooling costs, to impact the manufacture of future aero engine components. All of these factors will drastically reduce emissions across the life-cycle of the parts. …. Light-weighting, and the performance improvement of parts will result in reduced fuel consumption and reduced emissions….Impacts will include the development of high value, disruptive AM technologies capable of step changes in performance which will safeguard EU companies in the high value aero engine manufacturing field. AM will significantly reduce waste in an industry where materials require massive amounts of energy and toxic chemicals, in-process toxic chemical usage will be massively reduced, and emissions will drop because of the reduced amount of material involved.”








Source:

http://i.materialise.com/blog/entry/rolls-royce-is-going-to-3d-print-aircraft-engines

http://www.telegraph.co.uk/finance/newsbysector/industry/10448147/Rolls-Royce-looks-to-make-jet-engine-parts-with-3D-printers.html

LOHAN Vulture 2 rocket powered 3d printed DIY spaceplane

Low Orbit Helium Assisted Navigator's (LOHAN) Vulture 2 rocket powered spaceplane is near space aircraft lifted by helium balloon into high atmosphere. After release this 3d printed GPS guided spaceplane flies and lands powered by rocket engine to predesignated spot. Now, how cool is that?

Project and spaceplane  presentation:




Prototype test flight:



LOHAN Vulture 2 3d printed spaceplane



















LOHAN Vulture 2 coverage: http://www.theregister.co.uk/Wrap/lohan/

LOHAN Flickr photo stream: http://www.flickr.com/photos/registerparis/

LOHAN Vulture 2 mission summary:



They explored SLS 3d printing as production method and they made a video with SULSA from Suothampton University:



Here is first post on Southampton Uni 3d printed SULSA airplane:

http://diy3dprinting.blogspot.com/2011/11/3d-printed-aircraft-from-university-of.html


Also, do keep in mind students who developed and successfully tested 3d printed metal rocket engine:

http://diy3dprinting.blogspot.com/2013/10/students-developed-and-successfully.html

Future of space exploration is DIY and 3d printed.

Update (6.9.2014.):

LOHAN crew has new video out, with more material, tests, autopilot simulations and mission summary.




DMAV - RC aircraft with fully 3d printed airframe

Disposable Miniature Air Vehicle (DMAV) is cool small fully 3d printed airframe (no structural support elements like metal rods)  RC aircraft made by students.























From project site:

Nathan Kidder, Ben Rhoads, and Brian Jackson are student interns in the AFRL Discovery Lab program directed by Dr. Rob Williams. The program is a partnership between the Air Force Research Laboratory and the Wright Brothers Institute and is hosted near Wright-Patterson Air Force Base at Tec^Edge. Each year, the program hosts a multitude of interdisciplinary projects that are developed by teams of high-school, undergraduate, and graduate students. The DMAV project was part of a collaboration with the AFRL Aerospace Systems Directorate and the Dayton-Cincinnati chapter of AIAA.
During their 10-week research internship at the AFRL Discovery Lab, the trio was tasked with 3D printing a fully functional aircraft from a Makerbot Replicator 2X. The idea behind the project was that a plane could be quickly and cost effectively manufactured using 3D printing. The airframe could be printed for $16 worth of plastic in a matter of hours.
For the first five weeks of the program, the team designed and printed prototypes of their aircraft designs. With two Makerbots at their disposal, the team printed through five revisions before settling on an aircraft design they believed could fly. Stephen Warrener, an accomplished RC enthusiast, agreed to pilot the aircraft.
On the first flight of the morning, the 1.5 pound aircraft was handlaunched into a wind gust by Brian. After a brief session of controlled flight, the plane plummeted into the ground, snapping the nose cone into pieces. Undeterred, the Ohio State University students salvaged the motor and attempted to fly the second plane. "We knew the aircraft wasn't going to survive a landing. That's the 'D' in Disposable," Ben explained after the crash.
Stephen and Brian inspect the plane for damage after landing.
The second airplane, however, landed multiple times without crashing. The next flight was a success despite a rocky start. "It flew, but I was constantly fighting it," Stephen exclaimed after he recovered from a steep nosedive and landed the airplane. The plane went on to fly in two more one-minute flights before a landing which resulted in a fractured wing. The day's flight testing established the team as the first functional airplane with an airframe that was fully 3D printed (no structural aids such as carbon rods or otherwise) using an FDM machine. The aircraft was additionally the first 3D printed low wing plane to be flown. The first video below depicts the initial testing of the aircraft. The second video depicts testing following design modifications and the addition of an onboard camera.

Hopefully they will open source it.







http://wbi-icc.com/students/dmav/

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