All posts tagged: rapid prototyping

Realize Featured Project: 3D Printed Airplane Wing

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Realize, Inc. has been helping with the development of some very cool aerodynamic parts for the University of Illinois At Urbana-Champaign. We talked with Aerodynamics professor Phillip Ansel about the most recent wing project.

 

The Realize Featured Project: The 3D Printed airplane wing

 

Realize: Why are you making airplane wing prototypes? 

Phillip: We have started using rapid prototyping for creating wing and airfoil (the cross-sectional shapes that wings are made from) models, which we then test in our subsonic wind tunnel. By taking these models and passing air over the surface in our wind tunnel, we are able to simulate what happens when these wing sections are placed in flight. We will typically use various sensors to measure things like force, pressure, or flow velocity on or around this model. We then evaluate these measurements to determine how the flow about the model behaves, and what this means for the performance of a given wing section.

My research group specifically focuses on unsteady flows. Most research in aerodynamics is typically focused on understanding the average behavior of a given geometry over time. However, the flows about certain aerodynamic bodies can also have contributions that vary or oscillate significantly as time goes on, even if the object itself is stationary. There are several aerodynamic phenomena that have very distinct unsteady components of velocity or pressure, and my research group seeks to identify new ways to utilize these unsteady contributions. For example, the amount of lift that a given wing can generate is limited by something known as stall. If the angle of incidence of the wing to the flow exceeds certain limits, that wing will start to produce less lift and much more drag. Perhaps more importantly, an aircraft with a stalled wing is much more difficult to control. As it just so happens, the amount of unsteadiness in the flow increases significantly as the wing stalls. By measuring and identifying this unsteadiness we can develop a system to predict an impending stall and use various methods to manipulate the flow in order to prevent stall from occurring.

Our most recently-developed airfoil model is specifically suited for this purpose. We created the model with an internal cavity where we can install a set of pneumatic valves that can be switched on and off at a high frequency. Compressed air is passed through these valves, which then follows a snaking pathway to a set of blowing slots on the surface of the airfoil model. This is where rapid prototyping is particularly useful, since manufacturing these blowing slots using other methods would be difficult to say the least. We also designed the model to allow specialized sensors to be mounted into the surface of the model, which allow us to measure the unsteady surface pressure. Based on what is measured from these sensors, we can identify an impending stall and control the flow around the airfoil by blowing air through the surface slots.

 

How often does your program use 3D Printing/Additive Manufacturing?

To date, I have worked with four different airfoil or wing models that have been 3D printed and tested in our wind tunnel facilities, and also have plans to develop more. We will typically have a specific experiment requiring a new model about every year or two.

 

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What are the challenges you face when creating prototypes?

The most pressing challenge we have when using 3D printing to develop our models is material warping. This is most prominent in regions where the printed material is very thin. Over time the material actually begins to deform. If this occurs, we cannot use the model any longer since it no longer conforms to the original aerodynamic shape. We have learned quite a bit about how to design our models to prevent them from warping and are improving our design techniques with each new model that we make.

 

How do you feel 3D Printing will affect the aerospace industry in the years to come?

3D printing will absolutely have a positive impact on the future of the aerospace industry. Sometimes the most challenging aspect of building an aircraft or spacecraft lies in the fabrication of certain components. I think that 3D printing will allow us to explore new methods of creating aircraft and spacecraft components to be lighter, stronger, and have improved capabilities. Moreover, I think that future aircraft and spacecraft will be able to use components that have been 3D printed on-site to allow for faster, easier, and cheaper repairs. This is already being explored on the International Space Station. Since space is so expensive and difficult to get to, astronauts are currently testing how 3D printing can be used on the ISS to help them with performing experiments and maintaining facilities.

 

What are the biggest challenges facing aerospace engineering?

Aerospace engineering is actually very diverse field that stretches across many organizations, disciplines, and objectives, so I can’t speak for the field as a whole. From my perspective, however, one of the biggest challenges facing aerospace engineering today is the speed at which we can feasibly adapt to new technologies and capabilities. The aerospace field moves extremely fast and new technological innovations are being developed increasingly regularly: so fast that it can be difficult for society to keep up. We are currently seeing this in the development of policies and established practices for UAVs and commercial space flight. One way that we can help to make these new innovations realizable in daily life is to encourage outreach and education about science and engineering to help people of all ages to understand what aerospace engineering is all about. By encouraging education and diversity in engineering we can increase the number of experts and quality of ideas in the aerospace field, making cutting-edge technology more realizable in society.

 

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How do you inspire future leaders in your field?

I like to inspire future leaders simply by showing them how amazing the aerospace field is. There are so many interesting aerodynamic phenomena that happen in everyday life that we don’t always observe, but when they are pointed out to us we can’t help but be curious. I’m still blown away by so much of what I see in nature, and I think it’s incredible all that humanity has been able to accomplish with aerospace technology. In order to share this with my students, I like to incorporate real-world examples and demonstrations into my teaching. This can come through use of a vortex cannon to provide a simple demonstration of how vortex ring structures are formed to a classroom of students or incorporating modern research problems in the classroom.

 

Tell me a little about the program at your school.

The University of Illinois at Urbana-Champaign is the flagship campus of the state’s premiere public university. The university is composed of 16 colleges and instructional units with over 30,000 undergraduate students and over 10,000 graduate students. The Department of Aerospace Engineering is a part of the College of Engineering at Illinois, and it offers undergraduate and graduate programs that are consistently ranked among the top 10 in the nation. Currently, over 450 undergraduate students and over 140 graduate students are majoring in aerospace engineering at Illinois. The department is home to twenty different laboratories dedicated to cutting-edge research in aerospace developed by faculty with extensive externally funded research programs. Our department is home to many internationally renowned faculty that play a role in the development of major advances in aircraft and space applications. AE at Illinois is committed to excellence and leadership in teaching, research, and service.

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mereedRealize Featured Project: 3D Printed Airplane Wing
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Robotics Team Visits Realize

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FHS ROBOTICS TEAM AT REALIZE INC

Realize, Inc is proud to support local science and technology students in the Indianapolis area.
We sponsor the Fishers High School Robotics Team. The robotics team is called TigerDynasty (FRC Team #5010) and is associated with FIRST (For Inspiration and Recognition of Science and Technology.)

Recently the FHS Robotics Team visited Realize headquarters to show off their new robot that we helped them to design. Realize provided the students with a tour of our facility while they were introducing us to their impressive robot.

Check out the video from the visit as they put the robot into action. Play Ball!

 

 

“We believe that robotics and 3D printing will definitely work together in the future. Even on this year’s robot used at the Boilermaker Regional Competition, one of our team mentors had a personal 3D printer and we utilized 3D printing to create a gyroscope mount for our robot. With that example, we believe that 3D printing and rapid prototyping will be crucial in the success of robots in the future.”

– Ryusuke Saito, the Vice President an co-founder of FHS Robotics Team

 

mereedRobotics Team Visits Realize
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Volvo Truck 3D Model

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The Realize Featured Project: Volvo Truck 3D Model

 

Realize, Inc. worked with Auto Research Center to create a 3D Printed model of a Volvo truck.

 

“When Steve (ARC) came to us for help we were very happy to be a part of it. This SLA project is especially unique because it is going to be on display in our customers lobby. These are fun projects for the whole team and when it all comes together like this- it is always exciting to see the finished model.”

 

-Alan Conlu, Sales Manager at Realize, Inc.

 


We asked ARC’s Engineering Manager, Steve Roskowski, a few questions about the project.

 

Realize: How did this project come about?

Steve: The Volvo truck model came about to fill a void in our OEM tractor inventory. We do quite a bit of testing for both aftermarket aero device manufacturers, fleets and regulatory agencies. Several had requested the 670 VNL for their testing, so we completed it to satisfy customer requests.

 

What do you plan to do with this prototype?

The model is now available for any customer to use to advance their knowledge of tractor trailer aerodynamics.

 

What makes this design different then what’s out there now?

So far as we know, this is the only publicly available wind tunnel model of the Volvo 670 VNL for rent.

 

Tell us about the design process and how much time is involved for a project like this.

We started the design by renting a full sized truck, bringing to ARC and laser scanning it. From there it was converted to surface files and the model designed from there. The overall design process took about two months. Before we release the files to you, we have the whole model built in the CAD world to check for interferences and fits.

 

The hardest part in the process of creating this prototype 3D model was?

The most difficult part is scanning such a large object. The physical size simply creates unique problems that we need to work around. Since we have scanned many other vehicles for the same purpose we have a good handle on it and can get to the solution fairly quickly.

 

Volvo VN670 Scale Model

mereedVolvo Truck 3D Model
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Realize the first in US to install Somos PerFORM

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At Realize we are always looking for the latest new products and technologies to provide our clients with the best and most effective tools for their projects. So it’s no surprise we are the first company in the US to use the new Somos PerForm material.

 

Somos PerFORM offers heat resistance and stiffness unlike anything currently in our portfolio. It’s the first composite material we’ve installed and we’re looking forward to seeing the applications our diverse clients find for it.

– Todd Reese, President- Realize, Inc.

 

For more information about Somos PerForm CLICK HERE

 

When your project calls for parts that require thermal stability, extreme accuracy and a quick turnaround, turn to our latest composite material — Somos® PerFORM. Available for both 355 and 365 nm photopolymer-based machines, parts made with this material exhibit superior sidewall quality, along with excellent detail resolution. In addition, Somos® PerFORM is exceptional for parts that are designed for wind tunnel testing and unique applications in rapid tooling.

Excellent detail resolution, Faster, easier processing & finishing Superior high heat tolerance Expanded applications, Ideal for a variety of applications.

With its excellent high heat tolerance, outstanding detail resolution and stiffness, Somos® PerFORM is the ideal material for applications including:

• Tooling • Electrical Casings
• Wind Tunnel Testing • Automotive Housings
• High Temperature Testing


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mereedRealize the first in US to install Somos PerFORM
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Realize Sponsors High School Robotics Team

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Realize, Inc. is proud to support local science and technology students in the Indianapolis area. Recently we sponsored the Hamilton Southeastern High School Robotics Team. We talked with HSE Physics/Pre-Engineering Teacher Jeff Wilkins about the program.

 

 Tell me about the HSE Robotics Team, What does your team do?

HSE Robotics, aka Royal Robotics, started back in 2005. That year, my Principles of Engineering (POE) classes participated in BEST Robotics (www.bestinc.org) and the Digital Electronics (DE) class participated in Botball (www.botball.org). The robotics club at HSE now participates in the VEX Robotics Competition (www.vexrobotics.com) and has been competing since 2010. BEST Robotics requires students to make a robot out of common materials from scratch. Plywood, PVC and some sheet metal are the main materials used to create these robots. My Engineering Design and Development (EDD) class still participates in this competition to this day. Botball is a completely autonomous robotics competition that requires the team to build a robot out of a lego platform and an iCreate (from the company that brought us the Roomba, iRobot). Students have 8 weeks to design, build and program a robot to complete the task for the year. VEX Robotics is where our after school Robotics Club will compete. This competition uses materials that are used in the PLTW program and the parts and pieces are premade, so designing and assembling a robot is very quick and easy.

Why is this team important for students and the school?

We have over 50 students participating in Robotics Club this year, as well as, 22 students in EDD that are participating in the BEST Robotics Competition.

How did the Realize Sponsorship help your team?

Your generous donation allowed us to purchase a GCC Laserpro Spirit GX laser cutter which is used for fundraisers for robotics club and to cut the main chassis of our robots for the BEST Competition.
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What do you love about Robotics?
Robotics is sports for geeks. It has all of the excitement, hard work, and practice of athletic sports and allows students to excel on a different playfield.

How can you see Robotics and 3D Printing working together in the future?
Yes, we will be using our 3D printer to create parts and pieces for an R2D2 that we will be building next semester. It allows someone to design the robot in a 3D modeling software and get a prototype very quickly without expensive and time consuming machining.

What do you think students need more information on regarding the additive manufacturing industry?
All of the different types that are available. Most just think of FDM because that is what we have at HSE, but there are so many other options out there.

If you could 3D Print anything, what would that be?

Well, since I own one, I can print about anything I want, but 3D printing a house out of concrete would be really cool. My favorite item to 3D print so far were a bunch of digital sculpts that the Tech Art Club at Fall Creek Intermediate students designed. They were very excited to get a physical model of what they had designed on their iPad’s using 123D Creature App.

 

*If you have any questions or are interested in sponsoring  you can contact Jeff.  [email protected]  317-594-4190 ext. 11521.

 

mereedRealize Sponsors High School Robotics Team
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