Design and fabrication of a hybrid surface-pressure airfoil model based on rapid prototyping

Purpose - The purpose of this paper is to develop and present a hybrid design and fabrication method based on rapid prototyping (RP) and electrochemical deposition (ED) techniques to fabricate a pressure wind-tunnel model with complex internal structure and sufficient mechanical strength. Design/methodology/approach - After offsetting inward by applied coating thickness, the airfoil model was modified with three pairs of deflecting control surfaces and 24 surface pressure taps and internal passages. The stereolithography (SL) prototype components were fabricated on SL apparatus and roughened by chemical treatments. And then metal-coated SL components of the airfoil model were created by ED technique. After assembling, a hybrid pressure airfoil model was obtained. Findings - Electrodeposited nickel coating has dramatically improved the overall strength and stiffness of SL parts and the hybrid fabrication method is suitable to construct the wind-tunnel model with complex internal structure and sufficient mechanical strength, stiffness. Research limitations/implications - Interface adhesion of SL-coating is poor even if chemical roughening is applied and the further research is needed. Originality/value - This method enhances the versatility of using RP in the fabrication of functional models, especially when complex structure with sufficient mechanical properties is considered. Although this paper took an airfoil wind-tunnel model as an example, it is capable of fabricating other functional components with other rapid prototyping techniques such as FDM, SLS and LOM.