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3D printed 400mm EDF project

Posted: May 11 2021 3:30pm
by SkyersJet
I am working on a project to 3D print a large EDF (electric ducted fan). Currently there are no specific applications but I have VTOL in mind. That's why it is large for better disc loading and the pitch is low for better static performance. However changing the blades to a higher pitch for forward flight is a simple task.

I use 3D printing (FDM PETG) in order to lower costs because an EDF this large would cost many thousands to machine out of aluminium or make out of carbon fibre. An aim of this project is simply to show it's feasibility because it is popularly thought that a 3D printed EDF this large would simply explode.

It has a gearbox in order to further reduce costs by enabling the use of a cheap, off-the-shelf inrunner instead of an expensive, custom wound low Kv inrunner or a bulky and heavy outrunner. Originally the gearbox was also 3D printed but I had to abandon that and now it is machined out of steel.

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Here are videos of the performance so far (all thrust is recorded in kilograms).






Re: 3D printed 400mm EDF project

Posted: May 26 2021 11:24am
by charlesmcnall
Well I'll reply back. This is awesome. great job.
Could you put into the text the performance you have seen so far?
It's harder for me to tease out the values on the gauges at work with no headphones.

Re: 3D printed 400mm EDF project

Posted: May 26 2021 2:06pm
by SlowCo
Nice project :thumb:

Re: 3D printed 400mm EDF project

Posted: May 27 2021 7:19am
by Jordan325ic
400mm! I know nothing about turbines but they do look good. Great work, what printer are you using and how many parts are in that build as shown?

Re: 3D printed 400mm EDF project

Posted: May 28 2021 10:08pm
by SkyersJet
charlesmcnall wrote:
May 26 2021 11:24am
Well I'll reply back. This is awesome. great job.
Could you put into the text the performance you have seen so far?
It's harder for me to tease out the values on the gauges at work with no headphones.
Hi, thanks for your interest! All of the data is summarised at the end of my videos. In the first video (thrust test 6) I recorded 20kg thrust at 7712W. In the second video (thrust test 8 ) I recorded 18.7kg @ 7471W. NB: Different scales were used for both tests + I think that the batteries were sagging by the time I switched scales so I don't know which result is more valid.

Re: 3D printed 400mm EDF project

Posted: May 28 2021 10:12pm
by SkyersJet
Jordan325ic wrote:
May 27 2021 7:19am
400mm! I know nothing about turbines but they do look good. Great work, what printer are you using and how many parts are in that build as shown?
Hi thank you! I use a Creality CR-20 printer to print the parts in PETG. There are 62 parts in the build.

Re: 3D printed 400mm EDF project

Posted: May 29 2021 8:49am
by Jordan325ic
SkyersJet wrote:
May 28 2021 10:12pm
Jordan325ic wrote:
May 27 2021 7:19am
400mm! I know nothing about turbines but they do look good. Great work, what printer are you using and how many parts are in that build as shown?
Hi thank you! I use a Creality CR-20 printer to print the parts in PETG. There are 62 parts in the build.
How do you like that printer?
I assume the impeller blades are all printed as one piece, so the limiting factor is the 220x220 build plate?
What methos did you use to bond the petg parts together?

Re: 3D printed 400mm EDF project

Posted: May 29 2021 9:04am
by SkyersJet
Jordan325ic wrote:
May 29 2021 8:49am
SkyersJet wrote:
May 28 2021 10:12pm
Jordan325ic wrote:
May 27 2021 7:19am
400mm! I know nothing about turbines but they do look good. Great work, what printer are you using and how many parts are in that build as shown?
Hi thank you! I use a Creality CR-20 printer to print the parts in PETG. There are 62 parts in the build.
How do you like that printer?
I assume the impeller blades are all printed as one piece, so the limiting factor is the 220x220 build plate?
What methos did you use to bond the petg parts together?
I love it. I don't know why it wasn't more popular than the Ender 3. It is not much more expensive while being far easier to assemble and is an all round better printer. Yes the print bed size is the only limiting factor. Most of the parts are screwed together except the intake ring which is glued together to save weight.

Re: 3D printed 400mm EDF project

Posted: May 29 2021 11:36am
by spinningmagnets
Here is a pic of a "segmented" stator, which allows each stator-tooth to be wound individually before the stator is assembled, which can increase copper-fill, and the speed at which robotic assemblers can wind the coils.

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I really like how you made a much larger assembly from segmented parts. This kind of thinking allows smaller and more affordable 3D printers to be used for a much broader scope of products. I also don't like the tunnel-vision some builders who are new to 3D printing, and they want to make 100% of a product out of plastic in one single print. I am a fan of combining multiple materials, such as laser-cut / water-jetted metal plates as reinforcement (aluminum, stainless steel, etc). Several 3D parts can be wrapped in fiberglass/carbon fiber cloth. An assembly os smaller parts can be sized so that the completed assembly can fit inside a section of large-diameter PVC pipe, etc...

Beautiful work.