Virginia engineers build mini Rolls-Royce AE3007 jet engine using 3D printer

The replica of a Rolls-Royce engine created by the engineering department of the University of Virginia costs less than $2000 in materials. This tabletop replica was made with a 3D printing device and produces the whirring sound of a real engine. Professor David Sheffler of the University of Virginia under whose tutelage this model was created opines that 3D printing will become a mainstream device in the near future.

Jet Engine made with 3D Printer

There are a lot of things that one can do with 3D printing. Creating a working model jet is only one of these. A turbofan jet engine is that which works by compressed air as opposed to the more conventional jet fuel. The thing to be borne in mind is that to start a turbofan jet engine, the entire engine should start spinning before ignition.

At the beginning of the project, Sheffler gave the students Computer-Aided Design files for all forty-three parts of the replica engine. This was, however, not half as easy as just implementing those instructions in a 3D printer. The students then proceeded to modify and improve those designs to make sure that the designed engine would work efficiently once printed. Sheffler also urged his students to build their engine parts within real aircraft tolerances and concentrate on those parts that require tighter tolerances, such as the fan and compressor blades which are within 0.002 of an inch. These are essentially made of plastic but used like real metal parts.

One may be surprised to know that the turbofan jet thus created runs at the same speed as the real engine upon which it is modeled. Typically, in such an engine the core will spin from 1500 to 2000 rpm. The MP Jet version is a working replica of the MP Jet Super Atom.The replica is thought to be better finished and is similar to the original one except that it has a different crank case and upper mounting lug shape. The spinner nut and propeller mounting bolt of the MP Jet version are also similar to the original but the outer appearance is somewhat different. The rear cover of this jet engine has an o-ring to ensure proper sealing. This ring is made of brass and a mildly connected rod.

The replica of a real jet engine is a great little engine in its own right. All previous attempts at making such models were unsuccessful since the engines had defective cylindrical fins and/or they were over compressed. However, these engines with 3D printing enhance and meet all the technical requirements of the next generation.

Via: PopularMechanics