High Bypass Jet Engine Fan

by CATIAV5FTW, published

High Bypass Jet Engine Fan by CATIAV5FTW Jan 17, 2016

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14662Views 5805Downloads Found in Engineering


A high bypass fan inspired by Rolls-Royce's Trent series turbofans. Designed in CATIA, sliced in Simplify3D, and printed on a Makergear M2. The fan blades print separately from the disk and are designed to slide in, just like a real fan. The blades can stand up on their own, and the whole fan can also balance on the blade tips as shown in the first picture. This was a totally unintentional bonus feature and would've been difficult to design for. The white spiral stripe is printed flat, then dipped in hot water to soften and form around the black spinner cone - this step is tricky, but the end result is amazing.

The clearances and gaps between the parts are as optimized as I could get them, so that parts aren't too tight or too loose. Be careful about where the slicer assigns the start and end of each layer, especially for the fan blades - I recommend starting/ending each layer at either the blade's leading edge or trailing edge. You can see on one of the fan blades in the picture where the layer seam went diagonally across the back. This model begs to be printed in multiple colors! Enjoy! If anybody has problems with parts not fitting, please comment and I can upload a revised file.

For source files, I uploaded this to GrabCad as well: https://grabcad.com/library/3d-printable-high-bypass-fan-1

Print Settings

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Printed using Hatchbox PLA. I didn't need rafts on anything, but I did have brims on the fan blades and annulus fillers. Fan blades don't require supports. The disk's supports are a nightmare to remove, but they're necessary.

How I Designed This

Designed using pictures. Blueprints and drawings from engine manufacturers are never publicly available for obvious reasons.

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I confirm that the adjustment of the blade feet on the hub is really too tight.
Otherwise, very beautiful room !!!
When is the engine going with it ? ;o)

Je confirme que l'ajustement des pieds de pales sur le moyeu est vraiment trop serré.
Sinon, très belle pièce !!!
A quand le moteur qui va avec ? ;o)

Your design is impressive!!
Could it be possible to add one more blade so it has 20 blades like the trent 1000 engine..?
That will be great!!

Apr 26, 2017 - Modified Apr 26, 2017

should i set support to 'everywhere' or 'touching buildplate'?

For which parts?

Woops, I was thinking of the disk there is some overhang on the 'hooks' on top

I would love to have this replace the fan blades in my stand up living room fan, would make for an awesome conversation piece!! Being new at this hobby, I wouldn't have a clue on how the hub would fit on let alone finding someone to modify this so it does?

Hi. The annulus filler REVERSED doesn't have the 2 hooks. Can you please correct this as I'm printing reversed fan blades. Cheers.

Would you be able to create a "version 2" of the disk which can be printed without the requirement of supports on the inside diameter? These supports are really hard to remove. Maybe you could change the inner rings/grooves so they have angled or radiused overhangs? Accept you'l still need support for the tabs on the outside.

I suppose I could just get rid of the stiffener rings inside. Can't really see them anyway.

Great idea! I'm about to embark on printing this fan with the intention of attaching it onto a desk fan in our office ! We are an office of aircraft engineers (including a couple of engine specialists) and really like your work.

Uploaded the revised part with the suffix "no internal supports" appended to the name. Best of luck! And be sure to post it - I'd love to see it. And thanks, probably a good sign that engine specialists approve my models haha. I just took one class on it in college...

Fantastic. Thank you very much!!

Hi Chris!

Nice design! Just One question... Did you use any support materials on the disk? I am getting quite a lot hangings... Especially with the inner rings.

Yes, I used supports for the disk.

what orientation should the annulus filer be printer can seem to find a good surface to sit on the print bed with no supports??

Upright for me was good. Had it in an angle so it only have to support the front two hooks

Awesome design!!! I'm printing this with my prusa i3 and the fan blade doesnt seem to be fitting in the disk i was wondering why only me have this problem. If you could help me with that.

My guess is that you're overextruding.

How do fix this problem? Thank you!!!

Find the extrusion multipler setting in your slicer and reduce it. Should normally be between .85 and .90.

Very easy to print model, well done. Is this fan stage in the same scale as your 3D Printable Jet Engine and is it compatible with it ? The fan stage in jet engine model seems to be one single part so I'm not sure. Regards.
Tomasz Janiga

This fan is about twice the scale as the fan on the full engine. It also rotates the opposite way.

This print looks awesome! I wanted to ask what filament you use? The grey look unbelievable

Hatchbox PLA. Silver, specifically.

This fan is compatible with your Old 3d jet engine?
i think this assembly it's better for more print quality

It's twice as big and rotates the opposite way, so it's not compatible.

Wowee!! That is insane! How big is it when printed at 100% size?

Oct 20, 2016 - Modified Oct 20, 2016
CATIAV5FTW - in reply to AvroArrow

About 11" diameter. I think the pictures make it look bigger than it really is!

That's what I thought. I just printed one of the blades. I love it!! At first I was a tad worried - I have a prusa i3 and I was wondering if I needed a bigger print volume... but its fine! Thanks! I'll upload a pic once I've completed it.
Oh yes - one other thing. What did you print it in? Will PLA be pliable after soaking in hot water (to make the spiral?) What about ABS?

Glad it's printing well for you so far. I did PLA. That will soften up enough to do the spiral. ABS is a higher-temp plastic so the hot water trick won't work. Maybe print just 1 or 2 layers on that, so it'll be flexible enough to wrap around the cone.

Well done! I used to build the real thing and you have got this design pretty much spot on. Cheers!

Hi! Cant figure out how to print the anulus filler :/ It needs supports (difficult to remove everywhere). All help is appreciated

What orientation are you printing it in? I printed mine vertically, the same orientation as shown in the 14th picture above. Just needed supports on the 2 connecting arms, and a brim around the edge contacting the build plate. It's not an easy print, so plan on printing extra to account for a few bad ones.

It looks awesome! I also made a similar one that is electric powered. I like how good the attachments of the blades are.

I printed a fan blade out and it came out pretty good..there was a small patch of material on the pressure side of the blade just above the root where it was produced slightly sunken compared to the rest of the surface..not sure if it is the file or my printer (cheap turnigy fabrikator)...other than that it came out really nice scaled at 80%. What is the best way to print the main hub? I assume print it with the Z axis aligned to the axis of the hub itself as opposed to the way it comes in?

Was there not enough infill?
I printed the main disk with its axis aligned with the z axis. It's aligned with the x during modeling, that's all. Post pics when you're done!

Feb 9, 2016 - Modified Feb 9, 2016
elitetux - in reply to CATIAV5FTW

I printed with 15% infill I believe..it looks more like the outside vs the infill. I'm still pretty new to 3d printing so it very well could be my setup. I uploaded a picture of the blade for clarity. I printed out pie slices of the hub at different scales to verify that the blade would slot into the hub. I couldn't properly get the blade to slot into an 80% scaled hub (same scale as the blade) after a few different scales I was able to get it to slot into a 95% scaled hub...I am printing out the full hub right now ( at 95%).

what the best way to print the blades? i having a bit of a problem!!

Print it in the orientation shown in the blue file preview above. To keep it stable and stuck to the bed, i added several brim outlines. What have you tried so far?

Comments deleted.

Wuau! Great design :D Thank you for sharing. I am planning on puting a shaft on bearings and maybe an DC motor on the end of it. Probably some kind of inertia wheel made of shreading old printings... Thank you, your work is highly appreciated!

I would love to see this :)

very nice, i work on trent 900s at work, so i def recognise it all, wasnt expecting the annulus infills, thats a nice touch, as is the proper curve in the dovetails! cant print it though, id be labelled a raging aerosexual at work!

Trent engines are my favorite, though GE's new engines come close. Aerosexual, lol! Go for it, you will not be disappointed!

yea on days off now, might have to, pick up some new filament to do it some justice too...will post pics once i do print it!