Design and manufacture methods of rapid prototyping wind-tunnel models based on photopolymer-resin

Purpose - The purpose of this paper is to present a novel method to design and manufacture rapid prototyping (RP) lightweight photopolymer-resin models for wind-tunnel tests. This method can ensure the structural configuration similarity considering model deformation under aerodynamic loads. Design/methodology/approach - Photopolymer-resin based on RP technique was used to fabricate DLR-F4 models. Testing in a subsonic and transonic wind tunnel was carried out and the test results were compared to analyze performance predictions. Findings - RP photopolymer-resin wind-tunnel models fabricated by the design methods yielded satisfactory aerodynamic performance. The methods can decrease the model's weight and prevent resonance occurrence among the models, wind-tunnel, and support system, shorten the processing period, and lead to decrease in manufacturing period and cost. Research limitations/implications - Stiffness shortage of the thin components, such as wing tip, often leads to deformation occurrence under aerodynamic loads in transonic wind-tunnel tests, which has significant influence on aerodynamic characteristics of the test models. Therefore, model deformation should be taken into account in the design process. Originality/value - This design and manufacture method, aerodynamic and structural combination design and structural optimization, can obtain RP lightweight photopolymer-resin wind-tunnel models for satisfactory aerodynamic performance, which makes RP techniques more practical for manufacturing transonic wind-tunnel test models, considering deformation induced by aerodynamic forces such as lift force. The methods also present an inexpensive way to test and evaluate preliminary aircraft designs, in both academia and industry.