First Iteration

The first prototype iteration was printed completely in the Fortus Dimension printers in Jacobs Hall using black ABS material with dissolvable support. The housing was printing using SMART dense infill, while the blades, blade hub, and tripod mount were printed as solid pieces. Each print was done using the highest resolution possible. The blades experienced some deformation due to their thin structure, but these imperfections would be eliminated using the suggested method of injection molding production.

While both 3-blade and 5-blade versions were printed, the 5-blade design was chosen because of its significantly increased power output at identical wind speeds during testing. The final 5-blade design began producing usable power at wind speeds of ~6-7mph (5mA), and the maximum power acquired was around ~15-16mph (100mA). The turbine was not tested at higher wind speeds due to safety considerations of the 3D printed blades.

Demo Day

The complete prototype was presented at the Jacobs Hall showcase on May 03, 2018 using a standard camera tripod and floor fan to simulated wind conditions. The turbine was able to successfully charge several onlookers phones throughout the day!

Future Iterations

In subsequent prototype cases, stereolithography techniques with the Carbon printer can be utilized for better surface finish quality in the turbine blades. In addition, further studies can be conducted on the turbine blade designs in regards to the airfoil and other physical properties to increase the efficiency of the design.

The three blade turbine is still ideal since its most efficient and least amount of cost; however, further calculations would need to be done to decided not what is just most efficient, but most optimal for the average wind speeds.

The purpose of this design is have easy portability but mostly to ensure a working model that has high power output. Future models to come!

The team would like to thank Professor Taylor and the GSI Hannah Gramling for their advice and guidance throughout the semester.