Wind Tunnel Modeling with 3D Printing

Why use 3D printing for wind tunnel models?

Traditional wind tunnel model production can take weeks or months for a single model, limiting pressure tap channels location and arrangement, material options, and consistency while increasing costs. While various 3D printing technologies have been used for wind tunnel models for subsonic speed testing, they often fail to provide the necessary CAD design matching surface quality and accuracy, build volume for large-scale models, or the material strength and stiffness to withstand the rigors of wind tunnel testing. With SLA 3D printing technology, you can streamline the process and produce complex, high precision designs with surface roughness below 2um RA, fine pressure tap holes down to 0.023 inch (0.6 mm) and wall thickness down to 0.027 inch (0.7 mm).

Combine digital simulation, physical modeling, and experimental validation.

Wind tunnel testing works best as part of an integrated development cycle.

By combining Computational Fluid Dynamics (CFD), stereolithography 3D printing, and Particle Image Velocimetry (PIV), teams can simulate, build and validate designs more more efficiently and accurately, with higher correlation and predictability.

Virtual simulations refine geometry before printing. Physical models confirm aerodynamic performance in the tunnel. Experimental data feeds directly back into the next iteration.

Why the Neo^® Series of 3D Printers?

Engineered to overcome the limits of legacy SLA systems, the Neo® stereolithography 3D printer delivers the speed, precision, and versatility required for reliable aerodynamic testing.

• Large build volume enables the printing of large-scale aerodynamic components in one piece. Eliminating the bonding ensures part accuracy across the entire model essential for reliable wind tunnel testing data.
• A high-power laser with dynamic beam control produces high-fidelity parts with a smooth surface finish straight from the machine, removing the need for sanding prior to wind tunnel testing.
• Print complex, high precision designs with surface roughness below 2um RA, fine pressure tap holes down to 0.023 inch (0.6 mm) and wall thickness down to 0.027 inch (0.7 mm).
• Specialist material selection for advanced wind tunnel testing that produce parts with high stiffness, strength and the ability to withstand high temperatures which is essential for testing.