3D Printed Jet Engine

In specific applications, jet engines are often the most efficient internal combustion engines available. Not just for airplanes, but for anything that needs to run on a wide variety of fuels, operate at a consistent high RPM, or run for an extended amount of time. Of course, most people don’t have an extra $4,000 lying around to buy a small hobby engine, but now there’s a 3D-printed axial compressor available from [noob_sauce].

As an aero propulsion engineer, [noob_sauce] is anything but a novice in the world of jet engines. This design is on its fourth iteration with a working model set to be tested by the end of the month. Additionally, [noob_sauce] created his own software that was necessary for the design of such a small, efficient jet engine which has all been made available on Git. So far the only part that has been completed has been the compressor stage of the engine, but it’s still a very impressive build that we don’t see too often due to the complexity and cost of axial compressor jet engines.

Of course, there are some less-complex jet engines that are available to anyone with access to a hardware store and a welder which don’t require hardly any precision at all. While they’re fun and noisy and relatively easy to build, though, they don’t have near the efficiency of a jet engine like this one. The build is impressive on its own, and also great that [noob_sauce] plans to release all the plans so that anyone can build one of these as well.

Daedalus Jet Suit Takes to the Skies

[Richard Browning] wants to fly like Daedalus. To us, it looks a bit more like Iron Man. [Browning] is working on project Daedalus, a flight suit powered by six jet engines. These turbines are exactly the type one would find on large, fast, and expensive R/C planes. Some of this is documented on his YouTube channel, Gravity Industries, though RedBull has also gotten involved and have a video of their own that you can check out after the break.

The project started last year in [Browning’s] garage. He strapped a jet to an old washing machine to test its thrust. The jet nearly flipped the machine over, so he knew he would have enough power to fly. The suit started with a turbine strapped to each arm. Then it became two on each arm. This was enough for moonlike hops, but not enough for actual flight. Strapping an engine to each leg worked but was rather hard to control. The current configuration features two turbines per arm, and two on a backpack.

The whole setup is quite similar to [Frank Zapata]’s Flyboard Air, with one key difference – [Browning] is supporting two thirds of his weight with his hands. The effect is similar to supporting oneself on gymnastic rings, which is part of his extreme physical training regimen.

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Retrotechtacular: Railroads In The Jet Age

The front of the Soviet jet train on a monument in Tver, Russia. By Eskimozzz [PD], via Wikimedia Commons.
The front of the Soviet jet train on a monument in Tver, Russia. By Eskimozzz [PD], via Wikimedia Commons.
It started with one of those odd links that pop up from time to time on Hacker News: “The strange and now sadly abandoned Soviet Jet Train from the 1970s“. Pictures of a dilapidated railcar with a pair of jet engines in nacelles above its cab, forlorn in a rusty siding in the Russian winter. Reading a little further on the subject revealed a forgotten facet of the rivalry between Russians and Americans at the height of the Cold War, and became an engrossing trawl through Wikipedia entries, rail enthusiast websites, and YouTube videos.

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A 3D Printed Jet Engine Appears to Function

[amazingdiyprojects] has been working on a 3D printable jet engine. You may remember seeing a 3D printed jet engine grace our front page back in October. That one was beautiful didn’t function. This one flips those values around. [amazingdiyprojects] seems to make a living from selling plans for his projects, so naturally most of the details of the build are hidden from us. But from what we can see in the video clips there are some really interesting solutions here.

Some of the parts appear to be hand-formed sheet metal. Others are vitamins like bearings and an electric starter. We really liked the starter mechanism, pressing in the motor to engage with a spline, or perhaps by friction, to give the starting rotation.

What really caught our attention was casting the hot parts of the printer in refractory cement using a 3D printed mold. It reminds us of the concrete lathes from World War 1. We wonder what other things could be built using this method? Flame nozzles for a foundry? A concrete tea-kettle. It’s pretty cool.

We’re interested to see how the jet engine performs and how others will improve on the concept. Video of it in action after the break.

UPDATE: [amazingdiyprojects] posted a video of the engine being disassembled.

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Casting Turbines For A World Speed Record Motorcycle

[Anders] is going to beat the land speed record for a turbine-powered motorcycle. It’s a project he’s been working on for years now, and just this week, he put the finishing touches on the latest part of the build. He successfully cast the compressor for a gas turbine engine that’s twice as powerful as the one he has now.

This compressor piece was first 3D printed, and this print was used as a positive for a sand – or more specifically petrobond – mold. The material used in the casting is aluminum, fluxed and degassed, and with a relatively simple process, [Anders] came away with a very nice looking cast that only needs a little bit of milling, lathing, and welding to complete the part.

In the interests of accuracy, and just to make sure there’s no confusion, this ‘jet’ engine is actually a gas turbine, of which there are many configurations and uses. The proper nomenclature for this engine is a ‘turboshaft’ because the power is directed to a shaft which drives something else. This is not a new build; we’ve been covering [Anders]’ build for the better part of two years now, and although [Anders] intends to break the world record at the Bonneville salt flats eventually, he won’t be beating the ultimate land speed record – that title goes to a car – and he won’t be beating the speed record for all motorcycles. Instead, [Anders] plans to break the record for experimental propulsion motorcycles, or motorcycles powered by electric motors, steam, jet engines, or in this case, ‘turboshafts’.

It should also be noted that [Anders] frequently does not wear hearing or eye protection when testing his gas turbine engine. That is an exceedingly bad idea, and something that should not be attempted by anyone.

As an additional note for safety, in the video below of [Anders] pouring aluminum into his mold, the ground looks wet. This is terrifically dangerous, and steam explosions can kill and maim even innocent bystanders. This is not something that should be attempted by anyone, but we do thank [Anders] for sharing his project with us.

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Making the Case For Nuclear Aircraft

At any given moment, several of the US Navy’s Nimitz class aircraft carriers are sailing the world’s oceans. Weighing in at 90 thousand tons, these massive vessels need a lot of power to get moving. One would think this power requires a lot of fuel which would limit their range, but this is not the case. Their range is virtually unlimited, and they only need refueling every 25 years. What kind of technology allows for this? The answer is miniaturized nuclear power plants. Nimitz class carriers have two of them, and they are pretty much identical to the much larger power plants that make electricity. If we can make them small enough for ships, can we make them small enough for other things, like airplanes?

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3D Printed Turbofan Features Reverse Thrust

[Harcoreta] has created a 3D printed model of the GE GEnx-1B Turbofan. This is the engine that powers Boeing’s 787 dreamliner. What sets this model apart is that it has a complete working reverse thrust system. A real jet engine would be asking a bit much of 3D printed ABS plastic. This model is more of an Electric Ducted Fan (EDF). An NTM 1400kv 35mm brushless motor hides in the core, cooled by a small impeller.

jet-nakedWhat sets this apart from other jet models is the working reverse thrust system. [Harcoreta] painstakingly modeled the cascade reverse thrust setup on the 787/GEnx-1B combo. He then engineered a way to make it actually work using radio controlled plane components. Two servos drive threaded rods. The rods move the rear engine cowling, exposing the reverse thrust ducts. The servos also drive a complex series of linkages. These linkages actuate cascade vanes which close off the fan exhaust. The air driven by the fan has nowhere to go but out the reverse thrust ducts. [Harcoreta’s] videos do a much better job of explaining how all the parts work together.

The model was printed on an Reprap Prusa I3 at 0.1mm layer height. [Harcoreta] smoothed his prints using acrylic thinner, similar to the acetone vapor method. Unfortunately, [Harcoreta] has only released a few of the design files on rcgroups, but we’re hoping he will drop the whole model. We can’t wait to see a model dreamliner landing just like the big boys!

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