Search Results (107)

This study presents a compact, 3D-printed Savonius wind turbine rotor incorporating pointed deflectors to enhance concave-side airflow and mitigate blade-edge vortex formation. The prototype, fabricated from ABS plastic, was experimentally evaluated in an Eiffel-type wind tunnel under low-speed wind conditions (3, 4, and 5 m/s), with blockage effects taken into account. Flow visualization revealed improved airflow attachment and pressure concentration on the concave blade surfaces, increasing drag asymmetry and torque generation. Corresponding power coefficients with applied blockage ratio were observed to be 0.181, 0.185 and 0.186, while torque coefficients with applied blockage ratio were observed to be 0.385, 0.374 and 0.375 at each wind speed and optimal tip-speed ratio, respectively, and were compared with previously reported computational results. The optimal operating tip-speed ratios identified for the torque and power coefficients were remarkably close, enabling efficient torque and power generation during operation. The experimental findings validate earlier numerical predictions and underscore the importance of physical testing in assessing turbine performance. Observed deviations between predicted and experimental coefficients suggest that fabrication parameters may influence prototype performance and warrant further investigation. Overall, the results demonstrate the technical viability of 3D-printed Savonius turbines for small-scale urban energy harvesting applications in the Philippines. Full article

Global demand for adaptable and rapidly deployable construction solutions in offshore, coastal, and fluvial environments continues to rise, driven by pressing needs to develop energy platforms, improve coastal resilience, and support emergency response in the face of natural disasters. Increased investment in human-made coastal infrastructure, such as piers, support structures for power lines, offshore wind farms, and seawall protection systems, further underscores this trend. This study investigates the development of printable concrete mixtures for underwater environments using seawater as a replacement for freshwater, using a 3D printing syringe-based extrusion system. The effect of seawater addition and the printing medium (in air vs. underwater) was assessed via rheological and mechanical performance characterization. The results indicate rheological properties are favorable for seawater adoption by producing mixtures with higher yield stress and viscosity with the same levels of admixtures used for freshwater. Seawater-based mixtures demonstrated superior dimensional stability compared to freshwater counterparts, maintaining cross-sectional geometry, while compressive strength results showed no statistical differences between in-air and underwater samples. However, flexural strength was significantly influenced by geometry and printing medium. These findings establish critical rheological parameters for printable underwater mixtures and highlight the need for optimized curing strategies and layer bonding techniques to improve interfacial strength in underwater 3D printing applications. Full article

Rapid and precise intervention in disaster and medical-aid scenarios demands aerial platforms that can both survey and physically interact with their environment. This study presents the design, fabrication, modeling, and experimental validation of a one-piece, 3D-printed quadcopter with an integrated six-degree-of-freedom aerial manipulator robotic arm tailored for emergency response. First, we introduce an ‘X’-configured multi-rotor frame printed in PLA+ and optimized via variable infill densities and lattice cutouts to achieve a high strength-to-weight ratio and monolithic structural integrity. The robotic arm, driven by high-torque servos and controlled through an Arduino-Pixhawk interface, enables precise grasping and release of payloads up to 500 g. Next, we derive a comprehensive nonlinear dynamic model and implement an Extended Kalman Filter-based sensor-fusion scheme that merges Inertial Measurement Unit, barometer, magnetometer, and Global Positioning System data to ensure robust state estimation under real-world disturbances. Control algorithms, including PID loops for attitude control and admittance control for compliant arm interaction, were tuned through hardware-in-the-loop simulations. Finally, we conducted a battery of outdoor flight tests across spatially distributed way-points at varying altitudes and times of day, followed by a proof-of-concept medical-kit delivery. The system consistently maintained position accuracy within 0.2 m, achieved stable flight for 15 min under 5 m/s wind gusts, and executed payload pick-and-place with a 98% success rate. Our results demonstrate that integrating a lightweight, monolithic frame with advanced sensor fusion and control enables reliable, mission-capable aerial manipulation. This platform offers a scalable blueprint for next-generation emergency drones, bridging the gap between remote sensing and direct physical intervention. Full article

Transcranial magnetic stimulation (TMS) is a non-invasive neuromodulation technique extensively utilized in neuroscience and clinical medicine; however, its underlying mechanisms require further elucidation. Due to ethical safety considerations, low cost, and physiological similarities to humans, rodent models have become the primary subjects for TMS animal studies. Nevertheless, existing TMS coils designed for rodents face several limitations, including size constraints that complicate coil fabrication, insufficient stimulation intensity, suboptimal focality, and difficulty in adapting coils to practical experimental scenarios. Currently, many studies have attempted to address these issues through various methods, such as adding magnetic nanoparticles, constraining current distribution, and incorporating electric field shielding devices. Integrating the above methods, this study designs a small arc-shaped TMS coil for the frontoparietal region of rats using the inverse boundary element method, which reduces the coil’s interference with experimental observations. Compared with traditional geometrically scaled-down human coil circular and figure-of-eight coils, this coil achieves a 79.78% and 57.14% reduction in half-value volume, respectively, thus significantly improving the focusing of stimulation. Meanwhile, by adding current density constraints while minimizing the impact on the stimulation effect, the minimum wire spacing was increased from 0.39 mm to 1.02 mm, ensuring the feasibility of the coil winding. Finally, coil winding was completed using 0.05 mm × 120 Litz wire with a 3D-printed housing, which proves the practicality of the proposed design method. Full article

Waste prevention is at the top of the EU Waste Framework directive hierarchy. With this in mind, this article considers the application of novel technologies in the Cultural Heritage Restoration and Conservation field through environmental and circular economy principles. While previous research has explored the use of wood waste for composite materials such as building insulation and concrete additives, the suitability of degraded historical wood waste for filament production and 3D printing has not yet been addressed. This article contributes to this topic by studying the PLA/wood composite, material composed of a polylactic acid (PLA) polymer matrix reinforced with wood particles, produced from degraded historical construction materials. The paper describes the process of producing filament from bio- and moisture-damaged pine beam and oak parquet, followed by the 3D printing of historical platband replica. Research methods include photogrammetry, filament machine construction, filament production and 3D printing. The machines settings used in the process: heater temperatures were set to 140 °C, 90 °C and 105 °C; servo speed was 33 s; spool tension was 12.5; winding speed was 24 RPM; and screw speed was 9.2 RPM. For material preparation, a mixture containing 25% pine and oak sawdust and PLA dust was processed to achieve particle sizes of 312 μm, 471 μm, and 432 μm, respectively. Filament production was carried out with diameters of 2.85 mm for the pine/PLA composite and 1.75 mm for the oak/PLA composite. Finally, replica samples were fabricated using 3D printing. The dual objective of this research was to develop the method of 3D printing from degraded historical materials and introduce it to restoration practice as a wood waste minimization technique. Perspectives for further study include the testing of 3D-printed construction materials in outdoor conditions, and pellet production to achieve a higher wood content, compared to the filament thread. The processes described are adaptable to a variety of materials and disciplines. Full article

Vertical axis wind turbines (VAWTs) have significant potential for renewable energy generation, yet their operational efficiency is often limited by reduced aerodynamic performance and difficulties during start-up. This study investigates the effect of passive flow control and material selection on the performance of H-Darrieus VAWT blades, with the aim of identifying design solutions that enhance start-up dynamics and overall efficiency. Two-dimensional numerical simulations were conducted using the Dynamic Mesh method with six degrees of freedom (6DOF) in ANSYS 19.2 Fluent, enabling a time-resolved assessment of rotor behavior under constant wind velocities. Two blade configurations were analyzed: a baseline NACA0012 geometry and a modified profile with inclined cavities on the extrados. In addition, the influence of blade material was examined by comparing 3D-printed resin blades with lighter 3D-printed polycarbonate blades. The results demonstrate that cavity-modified blades provide superior performance compared to the baseline, showing faster acceleration, higher tip speed ratios, and improved power coefficients, particularly at higher wind velocities. Furthermore, polycarbonate blades achieved more efficient energy conversion than resin blades, highlighting the importance of material properties in turbine optimization. These findings confirm that combining passive flow control strategies with advanced lightweight materials can significantly improve the aerodynamic and dynamic performance of VAWTs, offering valuable insights for future experimental validation and prototype development. Full article

The advancement of onshore and offshore wind turbines depends on the experimental validation of new technologies, novel component designs, and innovative concepts. However, full-scale models are typically very expensive, have limited functionality, and are difficult to adapt to diverse research needs. To address this shortcoming, this article presents the design of a low-cost, modular 3D-printed small prototype of a wind turbine. It includes a multi-hollow platform for marine environments configuration and stabilization, the turbine tower, and three blades with active pitch control, not always included in wind turbine prototypes. The modular tower design allows for easy height extensions, while the rotor incorporates custom blades optimized for the prototype geometry and experimental setup. Tests were conducted to evaluate the system’s operational response and verify the proper functioning of the assembled components at various wind speeds and blade pitch angles. The results confirm that the rotor speed with the prototype’s onshore configuration is highly pitch-dependent, reaching a maximum efficiency of approximately 5°. The tower displacement, measured with an IMU, remained within a narrow range, oscillating around 2° and reaching up to 4° at higher wind speeds due to elastic deflections of the PLA structure. These results, consistent with the prototype scale, validate its usefulness in capturing essential aerodynamic and structural behaviors of the wind turbine. They also demonstrate its relevance as a new tool for experimental studies of wind turbines and open up new research, validation, and control possibilities not considered in previous developments by incorporating blade pitch control. Full article

This study presents the design, numerical analysis, and experimental validation of an innovative wind turbine blade incorporating an internal flow channel and tangential slots to harness the Coanda effect for enhanced aerodynamic performance. The primary objective is to improve thrust generation and lift while reducing drag, thereby increasing the efficiency of wind turbines and potential aerial propulsion systems. A three-dimensional blade model was developed in COMPAS-3D and fabricated using PET-G filament through 3D printing, enabling precise realization of the internal geometry. Computational fluid dynamics (CFD) simulations, conducted in ANSYS Fluent using a refined mesh and the k—ω SST turbulence model, revealed that the proposed blade design significantly improves pressure distribution and airflow attachment along the blade surface. Compared to a conventional blade under identical wind conditions (12 m/s), the innovative blade achieved a 12% increase in power coefficient, lift force of 33 N and drag force of 60 N, validating the efficacy of the Coanda-based flow control. Wind tunnel experiments confirmed the numerical predictions, with close agreement in thrust and lift measurements. The blade demonstrated consistent performance across varying wind velocities, highlighting its applicability in renewable energy systems and passive flow control for aerial platforms. The findings establish a practical, scalable approach to aerodynamic optimization using structural enhancements, contributing to the development of next-generation wind energy technologies and efficient propulsion systems. Full article

The subject of the research in this article were experimental tests of the M-346 Master aircraft model, carried out in a wind tunnel using the 3D printing method (FDM) in terms of the impact of surface post-processing technology on its aerodynamic characteristics. The measurements of key aerodynamic parameters concerned forces and moments in various airflow conditions taking into account variable angles of attack at a constant sideslip angle. The main purpose of the work was to verify the hypothesis that properly performed surface treatment significantly affects the accuracy of actual aerodynamic measurements in terms of solving the research problem using the post-processing technology, to conduct selected tests in a wind tunnel and analyze the obtained results. The obtained results of the tests, which showed a significant impact of the technological parameters of 3D printing and surface treatment methods on the correctness of the representation of real aerodynamic characteristics, were used mainly to analyze the aerodynamic performance of the model, verify the distribution of forces and moments, and evaluate the behavior of the structure in various flight scenarios. The obtained research results, the analysis of the obtained results, and selected tests were used to present important observations and formulate practical conclusions. Full article

Taking the leap to the secondary and tertiary generations of the missions to Mars, a comprehensive outline was presented for a cluster of Martian Habitat Units (MHUs) designed for long-term settlements of research crew in Melas Chasma, Valles Marineris, Mars. Unlike initial exploration missions, where primary survival is ensured through basic engineering solutions, this concept targets later-stage missions focused on long-term human presence. Accordingly, the MHUs are designed not only for functionality but also to support the social and cultural well-being of scientific personnel, resulting in larger and more complex structures than those typically proposed for early-stage landings. To address the construction and structural integrity of the MHUs, the current work presents a comprehensive analysis of the feasibility of semi-3D-printed structural systems using in situ material to minimize the cost and engineering effort of logistics and construction of the units. Regolith-based additive manufacturing was utilized as the primary material, and the response of the structure, not only to the gravitational loads but also to those applied from the exterior flow field and wind pressure distributions, was simulated, as well as the considerations regarding the contribution of the extreme interior/exterior pressure differences. The full analyses and structural results are presented and discussed in this manuscript, as well as insights on manufacturing and its feasibility on Mars. The analyses demonstrate the feasibility of constructing the complex architectural requirements of the MHUs and their cost-effectiveness through the use of in situ resources. The manuscript presents an iterative structural optimization process, with results detailed at each step. Structural elements were modeled using FEM-based analysis in Karamba-3D to minimize near-yielding effects such as buckling and excessive displacements. The final structural system was integrated with the architectural design to preserve the intended spatial and functional qualities. Full article

This paper catalogues a series of experiments we conducted to explore how to 3D print a DC electric motor. The individual parts of the electric motor were 3D printed but assembled by hand. First, we focused on a rotor with soft magnetic properties, for which we adopted ProtoPasta^TM, which is a commercial off-the-shelf PLA filament incorporating iron particles. Second, we focused on the stator permanent magnets, which were 3D printed through binder jetting. Third, we focused on the wire coils, for which we adopted a form of laminated object manufacture of copper wire. The chief challenge was in 3D printing the coils, because the winding density is crucial to the performance of the motor. We have demonstrated that DC electric motors can be 3D printed and assembled into a functional system. Although the performance was poor due to the wiring problem, we showed that the other 3D printing processes were consistent with high performance. Nevertheless, we demonstrated the principle of 3D printing electric motors. Full article

This paper presents the design, fabrication, simulation, and partial validation of a low-cost, fixed-wing unmanned glider equipped for temperature and image monitoring. Aerodynamic optimization was performed using XFLR5 and ANSYS Fluent 2023 R1, with spanwise variation between NACA 63(3)-618 and NACA 4415 to enhance performance. Wind tunnel tests of the selected airfoil showed good agreement with CFD predictions, with deviations within 5–10%. The airframe, fabricated using 3D-printed PLA with a cross-lattice structure, was integrated with an ESP32-CAM and temperature sensor. A reflective thermal coating was applied to mitigate the heat sensitivity of PLA. Propeller-induced flow was analyzed separately using the lattice Boltzmann method. Real-time flight behavior was simulated in a virtual environment via Simulink and FlightGear. While full in-flight testing is pending, the results demonstrate a scalable, open-source UAV platform for environmental monitoring and academic research. Full article

Traditional sand casting is limited by mold fabrication, cost control, and data collection, which restrict its further advancement. However, 3D sand printing technology represents a sophisticated rapid prototyping approach that directly utilizes three-dimensional models to fabricate complex sand molds and cores, thereby bypassing the traditional mold-making steps. This technology significantly enhances production efficiency and design flexibility, thereby advancing the modernization of casting processes. In the context of wind tunnel testing, the application of 3D-printed sand shell additive manufacturing has successfully produced sand molds and cores for the non-axisymmetric intake duct structures. This demonstrates the feasibility of this technology for complex casting applications and its capability to meet experimental requirements. Full article

A novel temporally resolved settle-plate air sampler was developed using 3D printing technology to improve upon traditional passive air sampling methods. Conventional settle plates provide cumulative measurements of particle or microbial loads over an entire sampling period, lacking the temporal resolution necessary to identify specific contamination events. The described device integrates a petri plate within a 3D-printed housing featuring a narrow slit that exposes only a small portion of the plate to incoming particles. A rotary mechanism, driven by a mechanical clock motor, rotates the petri plate over 12 h, allowing for time-segmented sampling. Validation experiments demonstrated the device’s ability to accurately encode the temporal history of particle deposition using both aerosolized dyes and viable microbial spores. The device effectively correlated bioaerosol deposition with ambient wind conditions during outdoor sampling. The system is inexpensive (under USD 10), requires no specialized skills to assemble, and is compatible with existing settle plate methodologies. This innovation enhances the ability to conduct air quality assessments in critical environments, enabling data-driven decisions to mitigate contamination risks. Full article

Following the promising performance of the seamless morphing trailing edge (SMTE) flap and its internal actuation system, the elephant trunk mechanism (ETM), investigated through aerodynamic and structural analyses, this study presents an experimental analysis of the SMTE flap equipped with an elephant trunk actuation mechanism. The morphing wing model was prototyped using a 3D printer. Four elephant trunk morphing ribs were embedded inside the flap section, all covered with a flexible skin. The control system for flap actuation was installed in the wing box corresponding to four elephant trunk mechanisms using an appropriate graphical interface to control the SMTE flap deflections. The completed model was further tested in a subsonic wind tunnel to validate the numerical aerodynamic results, as well as the functionality of the elephant trunk mechanism in real conditions. The results confirm the reliability and practicability of the proposed elephant trunk mechanism for actuation, and a very good agreement was obtained between the numerical aerodynamic data and wind tunnel test results. Full article