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3D Printable Jet Engine

by CATIAV5FTW, published

3D Printable Jet Engine by CATIAV5FTW Feb 9, 2016

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424053Views 116853Downloads Found in Engineering

Summary

A model of a 2-spool high bypass turbofan. I designed the whole engine from scratch with visual cues to certain existing engines. For example, I think Rolls-Royce makes the best-looking fans, so there's some resemblance there... By the way, this model was featured on SolidSmack.

Several parts benefit from the use of custom supports. I included these supports in the parts as needed, and they are much better than a slicer's default grid-like support structures. However, certain parts (fan stator casing, for example) also have typical overhangs that still require normal supports that you'll need to apply in your slicer. All parts with the custom supports have (With Supports) at the end of the file names. If you'd rather not use these custom supports, download instead the parts with (No Supports) at the end of the file names.

The biggest parts were designed to maximize an 8x10x8 build volume. I uploaded cut-in-half versions of the biggest parts (fan casings and stand) so smaller printers can print this without scaling everything down. These parts are down at the bottom of the file list and have the word "cut" somewhere in the file names.

Each part was designed with a specific printing orientation in mind (see "Individual Components with Orientations.zip" for pictures). Due to the concentric fit of many of the components, the order that parts are assembled is very important. I uploaded a diagram with labels to all parts for reference.

Due to popular demand, I uploaded unsectioned, full-revolution versions of parts that had sections cut away (casings and stators, mostly). These all contain the custom supports and are contained in "Unsectioned Parts With Supports.zip".

I organized the file list to separate between parts with and without the custom supports. Please refer to the BOM (Bill of Materials, aka Parts List) for keeping track of what parts to print.

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I used some non-printed hardware, namely the fasteners (screws, washers, and nuts) and ball bearings. These are listed below with the links where I got each:

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This was printed on a Makergear M2, so the gaps and clearances that I designed in the model might not be optimal for your printer! If something is too tight or too loose, please notify me in the comments so that I can adjust them in my model and upload a revised file. Make sure your printer axes are as perpendicular as possible; otherwise, the engine will wobble and scrape as it spins.

Good luck and happy printing!

Thanks Max for the yellow engine rendering!

How I Designed This

Designed to minimize the need for supports as much as possible.

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Help with LPT section. I am assembling the LPT turbine section and once I slip the LPT casing on the rotor starts binding. I've sanded down the casing and the LPT stators (all stages) (including inner hub) with no luck. It'll bind and when I connect the flanges and very lightly snug it up it'll seize completely.

Does anyone have any tips on how to get the LPT rotating freely (I really need my N1 rotation :P)?

I'm wondering if I could get away with resizing the case in slicer by 0.5% and maybe lower the hub or something...(I'd be willing to try that but low on the case filament so I don't want to trial and error too much)

That said this is a great project and I'm loving it.

I tried to scale up the LPT case by 0.5%. I still ended up sanding a lot of the case and it was still rubbing. Maybe on the next one I'll try resizing the whole section. For now I'm just accepting the rub and leaving a gap between the LPT/Turbine case flange

I am having a similar issue with binding on the LPT turbine section. I added an offset (about 2 mm) between the LPT casing and nozzle casing but that is a crude fix from my perspective. I am also looking for a better solution to the LPT turbine binding as well.

Why isnt the top covered?

What exactly are you referring to?

What print bed size does the biggest part require?

8x10 inches, roughly. The split up versions of the big parts can accommodate smaller build plates.

Hi, at what layer height did you print the fan?
Thank you

Comments deleted.

Hello,
this such an insanely well executed project, well done. I am in aviation and currently getting my degree in CNC machining at my community college. I'm wondering if you would be willing to share your CAD files for this project? I'm dying to see if i could import it via .STEP File and make at least some of these parts on our machines at school. Would make for an epic semester project and id be sure to site you in the write up. Thanks, and again great work!

I appreciate the compliments. I'd love to see a machined version of this! Step files are zipped up on the bottom of the list of files.

hey there, anyone know if i can buy sealed bearings instead of open ones

Yes just look up how to make open bearings from closed bearings it takes about 2 minutes

They are available on Amazon, I'm pretty sure

How did you print this out to make it appear architectural like the fourth photo you included where everything appears to be micro beams and trusses or spiderweb style?

That was a combination of 2 separate images, one of them being the 2nd picture above and the other being a rendering of the model with the shading turned to mesh. I thought it looked dope.

Beautifully, and accurately detailed!

More than forty years ago, I was a Jet Engine Mechanic in the Navy. Seeing your design thrills me.

I would love to know how you did the 3D design of the fan, blades, and vanes. That eludes me.

Fantastic!

That's awesome! I made them in CAD using pictures of Rolls-Royce and GE engine fans for reference. The blades are basically multi-section lofts with leading and trailing edges defined in 2 views (front and side). They look complicated but are actually pretty simple.

I am currently working on a different model of a jet engine and I was wondering if you knew the make psi that a jet engine like this can handle since i am making mine to work off of air.

No idea, but I imagine it depends on the material you use to print it with and how much infill you use, as well as how tightly you're able to seal off the casings to reduce leakage. Would love to see it if you pull it off.

Hi there , amazing design!
Wanna print one , quick question: how much filament you used for it (approximately)? How much time (approximately ofc) It took you to print all of it?

Less than 1 kg, I think. And lots of time, since I did most parts individually. Maybe a couple hundred hours since I also print slowly for better quality.

Congrats on the design, been on my print list for a while. Printed the majority of parts now, bolted the outer casings together. Have assembled the rotating shafts however dont quite see how these now fit together? Any advice on assembly here? Am i assembling in the wrong order? Do all parts need to be assembled internally?

Thanks for any advice!

Hi!

First of all: Awesome design! I am currently in the progress of printing this design, which is challenging for me as a beginner, but an absolute must have!
I am printing the open design, but I think it would be cool to have the core "open and close" by means of a lid. Is it possible that you upload some new variants of the core case files? I'm thinking of the pieces that are currently cut away from the core case parts. If they would be available as printable parts, they could (when bolted together) serve as a lid for the core.

Should you find the time to create these parts: Thanks a bunch! If not.... no worries ;)

Hard to find the time, but maybe some others can pitch in and upload a remix...

hey guys ! very nice work !!! amazing
So i have a question for you, witch ball bearing do you use ? (100% model)

Specific bearings are contained in the description

Can this work with electricity and actually work?

There's a remix where someone did this

Hi, I'm a corporate jet pilot and congrats on such a great design! Question about printing the fan. Did you have any issues with zits and blobs on both sides of the fan blade? If so how did you solve the problem or did you just do a post sand on the blades? Thanks again for an incredible job and very true to scale.

I made sure to put the layer starting location along a more or less vertical line going up the hub.

I’m using Simplify3d, is there a setting under Layer tab to specify? Thanks again
I also set the coast setting and retraction setting as you had specified in another answer to someone’s question.

Go to the layer tab, then Start Points section, then pick the 3rd option, "choose start point closest..."

Comments deleted.

Hello! First of all, congratulations for such a incredible design.
Could you provide me the exact number of screws, flat washers and nuts?
Thank you so much!

77 screws, 77 nuts, and 146 washers

Great Design!!!!
I'm trying to build a lamp out of this and I was wondering if you could post a cover for the whole jet for make it work better as a a lamp.

There are some remixes of this where other people uploaded covers they modeled for this.

Could you upload the stripe that would match up with the spinner so it can be printed using a dual extrusion printer? Not that is that much harder to do but if the part is made already and just has to be uploaded that would be a nice touch. Absolutely incredible work!

Thanks. There's a remix where someone posted a dual-color spinner.

Hello, first, thanks for a very fun and detailed model, I'm in the process of printing parts on my new Prusa mk3. Could you tell me what software you used to design this model and if you have any tips for a noob (me) in 3D design? I would like to try my hand at a cutaway SR-71 engine similar to your model.

I appreciate any comments,
thanks
Phil D.

I used CATIA. As far as tips, I suggest searching for tutorials on youtube and finding CATIA (or other CAD) textbooks. And then just spend a lot of time modeling things. Good luck with your project!

What printer did you have?

Comments deleted.

First off; incredible design! Still chugging along trying to print all the parts on my Prusa MK3.

I'm new to 3D printing and still tweaking some things, but how does everyone deal with the Combustion Lining w/ Supports? I'm finding it difficult to remove the support structures that are internal to the lining. So far all the pieces have printed just fine without much issue removing support structures (default and custom). So I'm not sure if this is just a bad print and I need to redo it or if its just something that difficult.

Thank you in advance for any advice.

It's printable without the need for supports inside the combustion lining. Only need supports for the thin overhanging flange. I designed the parts such that any angled surfaces are doable without supports, and only the horizontal overhangs actually need supports.

Is it possible to use some zippy fuel and actually get this going? If so how would I go about doing this? Great design btw.
~Luke

I'm pretty sure getting the combustion just right to make it run and continue running (self-sustaining without a starter motor) would be the biggest headache. Probably find someone who works with scale model jet engines for RC planes and get their thoughts.

Thanks Man! I was planning on CADing an rc jet or something around the engine anyway. How would you go about using a starter engine specifically in your design. Thanks for your hard work on this. It is people like you that make me want to be an aerospace engineer when I grow up.

Comments deleted.

can you upload a fully assembled stl version? thanks in advance.

What will you use it for, if you don't mind me asking?

I will be making a version that is a spool holder that operates when you are printing!

how big is this and how many hours did you spend printing this?

14 inches long and 150-200 hrs, depending on how many parts you print at a time.

Hi.
Trying to print your design, Whats the different between" with supports" and without supports. I am using Cura 3.do I leave the supports clear.
or what.
I have obtained the 4 Bearings as per list. Where do they fit.?
Thankyou
peteralfe

The ones "with supports" have extra supports to better handle certain features. I highly recommend printing those. You still need to have regular supports added on those parts though. Please refer to the section views for bearing placements.

How do you remove the custom supports? Or do you have to do something in the slicing software to print them as support instead of solid?

Thank your, help is much appreciated. I am having much pleasure in my attempts to print
your fantastic design. Your skill is much admired.
peteralf

You dont have youtube link? How to assemble it?

Hi Catiav5ftw, first amazing design. I am enjoying to print it.
I have one question: i have printed the fan that you have designed separately to this model but I cannot find the bride to Connect it to the rest of the engine.
Have you created one or not?
If yes is it possible to share the file?

Thanks in advance.

Eric

The fan model is a completely separate project, so it won't fit this engine (it's too big and spins the opposite direction).

Thank you so much. I will try to redesign it in order to fit with the engine.

Hello, I have a Prusa MK2S and MK3 and printed 3 of your turbines. Would it be possible for you to reduce the outside diameter of the following files by 2-4mm. The parts print great, but the tolerances are too tight an bind when I assemble the turbine.

LPT_Stage_1, 2, 3, 4_No_Supports.stl

Also, would you be able to reduce the shafts both Front and Aft, where the bearings sit (17mm and 20mm) by .25mm. Again, thank you for creating such a great model.

Regards,
Michael

Hi - Im having a couple of issues getting the flat stripe onto the spinner cone. It fits perfectly but is far too springy to stay in place and as a result breaks the glue! Any tips? Im using PLA and 0.08 layer height if either of those make a difference.

Use a heat gun or hair dryer to soften the stripe, then form/wrap it into the groove. You still need to glue the ends, but this way there is little force pulling up in the ends.

Maybe reprint the stripe but only do a few layers instead of the whole thickness.

Ill give that a go when I load the printer back up with white - just powering through the turbine stages now! Its a big old print.

I am also having problems printing the Fan Stator Casing with support and than using supports in Slic3r Prusa Edition for the other overhangs. It's the last part I need to print, all others printed fine with support from Slic3r and your included support, but the Stator casing is having big issue's. Could you make one version where no supports from the Slic3r are needed? I think that would solve my issue's.
The one you made still requires so much supports from the Slic3r that the chances of one failing are very high I guess.

I would appreciate it very much, as the model itself is great and I would like to finish it by printing the last part, I also have all the bearings as well.

Thanks in advance!!

I'm guessing it's adding too much support. Only the overhanging surfaces that are horizontal actually need supports (see areas highlighted in orange in the attached pic).

Yeah I have played around with the settings so I also tried minimal supports in those area's but there are still soo much that somehow it creates problems.
I think a solid support like the others you already added helps solve that for me.

It really is the last part I need but somehow I can't get it to print right.

Nevermind, I finally managed to print the part, sliced in Slic3r PE, the trick was to print it slow, at 50% speed and to use 0mm between supports and the part itself and a solid top layer of the supports. The inner floating ring wouldn't stick on the supports with the default 0.15mm gap that Slic3r PE sets, this would make the print head catch on the ring and cause serious problems with the print.
Hopefully I can remove the supports but I think it will take some effort to make it clean, at least the part printed.

Comments deleted.

First of all, awesome model mate!

I have just a little question - is there any chance, that there is a model or parts for remaining section view that completes the model? to describe what I mean - I would like to print this luvly thing these days and I have been thinking about version which is completely closed but you can pop the whole thing up and that would be great with the use of neodimium magnets... so closed model - POP! - section view. I could probably try this myself, but there is no more spare time to do that :(

thanks for the answer and for the awesome job you did here :)

Hard to find the spare time for that myself, but that sounds like a cool idea.

Hello, Thank you for designing such a great turbine. I have a Prusa Mk2S and have made 2 of these turbines in the past 6 months, I posted pictures of my first one in April, 2017. I've had the same issue with both. The tolerances between the HPT and the LPT Stage 1 are very tight. Also the spacing between the LPT Stator Stage 4 and the Nozzle are also very tight. I've tried to change the height (Z) of the parts but this seemed to make it worse. Can you reply with a solution to try.

Also, I'm not sure if this is an issue with my printer but the tolerances of the LP Shaft front and Aft are Too accurate. What I mean is the 17mm and 20mm landings where the bearings mount are exact. I have to sand the shafts to make the bearings fit. Is there a way to reduce these ares without affecting the other dimensions of the parts.

Could you provide me with a working PLA GCode for the Fan Stator Casing? I tried printing it on my Prusa i3 MK2S, but it keeps failing with the Slic3r PE supports.

Thanks in advance!

I have the GCode you're looking for. I had to use a really old version of Cura to get the part sliced properly with all the supports. I will send the file later tonight when I'm home.

Perfect! Thank you very much, can't wait to finally print the last part and finish the model.

Again thank you!!

Here is the file you asked for. Let me know how it works for you. I printed this part at .2mm layer height, 20% infill, 60mm/sec. The print time was about 19.25 hours (I think..)

Something is very wrong with what you send me, it starts printing mid air, no meshbed leveling. Your starting GCode is totally different than what I was using in the past.
Do you know what is happening?
I tried editing my own start GCode but that get's even worse.
Your help is appreciated.

I have no idea why this would start in mid air. I have used the same Gcode for all 3 of the turbines I built. I will do a test print tonight with the same code and let you know the results. I'll also resend the file if this prints correctly.

Not sure if it would make a difference but I use Octoprint to print the file.

I'm not using Octoprint yet. Are you just copying the file to your SD card and printing from there?

Yeah I tried both with the same result, they both start printing wel clear of the printbed and no meshbed levelling before.

Here is the file again. I'm going to start this print again and take some video. Let me know if you want to see.

Yes I would like to see that, the file is exactly the same as you send before so I don't see how this will work with the MK2S without meshbed levelling.

Sorry I was not able to take video. I have attached a picture of the test print from last night.

Thanks for that!
So you never meshbed level when you start a print?
You have set your Z using the calibration on the SD or in the firmware?

Really strange, although I do see some issue's with the print in your picture as well.

Sure, sorry to hear this is not working for you. My printer goes through all 9 calibration points before each print. Live Z was set by using both the V2 calibration and a few different test prints. I'm fairly new to 3D printing, only about 6 months. I'd be interested in your comments about the issues with this print from the picture.

Nevermind, I finally managed to print the part, sliced in Slic3r PE, the trick was to print it slow, at 50% speed and to use 0mm between supports and the part itself and a solid top layer of the supports. The inner floating ring wouldn't stick on the supports with the default 0.15mm gap that Slic3r PE sets, this would make the print head catch on the ring and cause serious problems with the print.
Hopefully I can remove the supports but I think it will take some effort to make it clean, at least the part printed.

Thanks for your help!!

Good to hear you worked out the issue. I have printed this part a few times without any issues removing the supports. Please post a picture when you have this assembled.

Due to no gap at all between the supports and the part itself, the top and bottom of the supports are fused with the part itself so will require some more work to clean up, but that's ok I am happy it printed at least and I can finish it.

I had the same issue when I used Slic3r PE. The part was printing with a wide brim that was fused, even with the setting turned off. I know I'm half way around the world from you, but if you want me to print one for you message me. I am able to ship all over the world.

Thank you for the offer, but I am able to clean the part up nicely, will just take some TLC. ;-)
I don't have a brim, it's just the supports that needs cleaning up.

Ok, have a good day.

Again thanks for all your help!!

Strange as the command to perform it, G80, is not in your GCode.

One of the small supports is missing in the inner ring, some of the lines seem to be messy or missing here and there, mostly the outline though. But that might all be due to Cura, I never really used it.
I'll try some more, maybe slowing things down will solve my issue's.

Thanks for your help anyway!

Awesome mate!!
I'll give it a go.

That looks great!

The fan still has some of the supports attached, did you do that on purpose?

Yes, that's intentional. I've printed the fan a few times. I removed all the supports and didn't like the way the part broke off the blades. I feel this looks better. Maybe there's someone that has a better way to remove the supports without scarring or breaking the baldes.

Hi, could you please upload this model fully closed as well ??
i personally would only need the parts w.o. support in the files, so if you could do it i would be really happy :)

If you print fully closed parts, it would actually be impossible to assemble (stators inside the casings, specifically). It's possible to do 2 casing halves and put them together (like engines in real life) if that's what you mean.

Hi. Great work. I was interested in using the front blade section from this model for an art competition. There is the potential of cash prize so if you deem that as commercial use would I be able to get your approval as per the thingiverse policy? Thanks

I wouldn't consider that as commercial use, so it's fine.

Thanks so much.

Just finished my one. First of all: Thank you for this awesome model. Mine looks really great. I went with Patona White, Fittingslot silver metallic, Extrudr.eu matte black and an Ice Filaments Oak woodfill stand. It just looks great.

Unfortunately i had a lot of issues with the bearings, so it ended up more of as a static model as it wobbles pretty terribly. Later in the building process i found out that i had to sand at least 0.5mm to get my bearings to fit. On the very first bearing i just tried to use force and it went half way in but didnt want to go any further or go out again. I had to carefully hammer it in, which was pretty nervewracking and apparently it didn't end up perfectly straight.

Also, i think instructions would make everything so much easier, even though admittedly I have very little experience putting models together, so maybe it's just me. I made so many mistakes with the order of putting things together that i had to keep unscrewing things because of not being able to reach some parts i still had to screw in. A simple step-by-step text instruction manual would have been a lifesaver for me.

Printing wise it was challenging but doable. I ended up using mostly my own supports as the provided supports kept fusing together with the model too much. Also, the big fan blades came out really terribly with a lot of blobs and zits, while every single other part of the model printed perfectly fine. First i thought it was the filament, but it came out exactly the same with another filament. The second filament allowed removing most of it with a scalpel without leaving marks though, so it was a lot of work, but ended up looking nice.

For anyone in germany who wants to buy screws: Look for ISO 14583 M 2,5 x 10 screws, DIN 439 M 2,5 Nuts and DIN 433 2,7mm washers. And the bearings from amazon.de that i had issues with are the ones by Kugellager Shop CQ Stuttgart. My printer being the problem is also possible though.

Did you use PLA? The issues you described sound to me like the printer was overextruding. There are a couple videos of people putting theirs together. One of them is here: https://www.youtube.com/watch?v=5hD_ZGOuvJE

I do know that another user here is working on an actual step by step instruction video and should be available soon.

Yeah, i did use PLA. Overextruding is something i have to check on, but most parts came out great, and the last time i made the makers muse tolerance test, i got down to 0.2. Maybe it's the rather cheap filament i'm using. Might be an issue with diameter tolerances. I'll check that and i'll also measure the parts that are reachable to see how much the outer diameter increased compared to the model.

Did you only use silver, black, and white filament? Are the fans all one grey color? I like the look of the picture you posted and want to replicate it.

Yes and yes. Good luck!

would a Radial Ball Bearings work too instead of open ball bearings?

Radial ball bearings are the same.

would a Radial Ball Bearings work too instead of open?

Aren't those the same thing?

Hi.
How much filament do I need for this?

Not sure actually, and it would depend on the infill. I hope someone else here who's printed one has the answer.

Thanks!
Great design!!

This model looks amazing, and I have had excellent luck with printing almost all of the parts. Unfortunately I am having some issues, with printing a few parts, where Cura isnt creating toolpaths for the support material. The two parts I have really noticed this on were the main Fan, and the Fuel injector, although there were 1 or 2 others that had missing support but printed fine nevertheless. On those two files though, the support shows up in Cura and looks fine, but if i look at it layer by layer, it omits the support material. Any ideas on how to fix this?

Thanks again!

I had issues printing the fan stator casing. In Cura, I had to raise the model .4mm and then the supports and everything else printed properly. Not sure what the deal was.

I had no issues with the main fan. In fact, I didn't add any supports - just printed it with the included supports.

I've heard of a few others having trouble with the fan stator casing in Cura for some reason. I use Simplify3D with no issues. I'm not really sure why the supports cause so much trouble...

And correct, the main fan doesn't need additional supports apart from the custom ones I put in already.

Is there a shroud that can be used for this model?

I haven't made one, but there is one in the remixes.

Hi. English is not my first language so i didnt compleaty understand your describtion. If i look at your exel table, sectioned engine with supports is the table that i should print right, if i want to use your custom supports for easier printing. Also are there any instructions as to how to assemble this thing after i have it printed. Also i like your white, black and grey scheme a lot. Do you have a list that shows which item should be printed in which colour? Thanks for the aswers!

Yes, sectioned engine w/ supports is what you need. I don't have instructions, but this youtube link https://www.youtube.com/watch?v=5hD_ZGOuvJE shows another guy putting his together.

I don't have a list of what parts are which color, but generally, all the casings and spools are white, parts with blades are gray, combustion area is gray, and nozzle cone is gray.

Thanks for the great looking model by the way, I was wondering if i could get this running by any chance, i have no clue about how jet engines work and I figured why not make one and experiment with it.

This engine is just for looks, and the plastic would melt if you tried to run fuel through it. If you look through the remixes, you'll see a motorized version.

just theoreticly, if "someone" would build this thing out of ... steel i guess ? and as well fully closed. would it run ?
i mean there are pleanty of homemade jet engines but none of them is really working so i was just wondering ^^,

Running, like with fuel? No. Running from an external electric motor to just spin? Sure, why not

Hello!
first up amazing model mate and really well designed.

Just hav 3 questionsif you wouldnt mind answering

  1. I need to scale this down to 50% original size. Will all the pieces and the model go together fine?

  2. I am using your reccomended list on the excel sheet. And wanted to now exactly which parts needed support throuhh cura added? I dislike supports as the model never looks as clean. But which ones need them?

  3. I love your coloring man so wondering if you could tell me which components where the white ones and which ones silver.

Thanks mate!

50% would be pushing it. The clearances between the parts would be super tight, and tolerance issues from any printing imperfections, axis misalignment, and inconsistent extrusion, etc. would keep the engine from spinning well. Plus, the fastener holes would be tiny, and I don't know if they make screws small enough. Also, I don't know if there are properly sized ball bearings either. And the custom supports would be too thin to print at 50%. Some others have printed down to around 60% scale, but I'd really recommend full scale.

I don't know which parts need supports specifically, but basically anything with flat surfaces facing the build plate would need supports (casings for example). I designed the parts such that most, if not all, of the angled surfaces don't need supports.

My coloring scheme was all the casings and spools are white, whereas anything with blades is silver. Combustion chamber and nozzle cone are also silver.

By the way, I have problems fitting the strip to the spinner cone.
Is there a tip for that or a chance for spinner cone with the strip for dual color printing? :)

Did you print it in PLA and do the hot water trick? I can upload a dual color spinner, although I can't promise it very soon, unfortunately.

how hot the water should be? will it also work for the tip?

Just hot enough to be uncomfortable to dip your finger in, but not boiling. The tip shouldn't need it.

Hello, do you still have the original cowlings (front & back) at 100% with thin walls?
Thank you

Could you clarify? I did 25-30% infill for everything.

I have redirected my question to https://www.thingiverse.com/thing:2147061.
BTW I have printed the engine and am very happy with the quality and attention to detail you provided.
I admire your talent and dedication in designing this model. Thanks very much for making it available to us.

JET ENGINE
by Kamzo

Are there any recommended settings for the print?
Such as layer height and speed?

I printed at .15 mm because it's a good blend of high resolution and faster print times compared to .1 mm. I also kept the print speeds low (10-12 mm/s outlines) to improve surface quality and reduce ghosting around corners.

I am having difficulty in Cura with a few parts. Specifically the Fan_Stator_Casing_and_Support_With_Supports.stl

When I import into Cura and lay the object flat (with support on bottom of course), in the layers view, it does not want to print the first support layer. See image attached. You can see on Layer 1 it omits your included supports for some reason. Can anyone explain how to fix or get around this? Thanks

I'm not sure why that is. Sometimes, Simplify3D omits layers randomly in these parts, but I found that rotating the model helped for some reason. Other times, I had to remesh the part. Did you find a workaround? Looks like your model printed well.

Comments deleted.

Hello,

insane modell! Ive printed all parts, started assembling like in the video you posted. On the shaft the HPC Stages are put and the HPC Casing is filled with the stators. Now my question is to get the shaft inside the casing between the stators. Is there any trick? Since it is not open 180° im afraid of breaking the stages.

I put all the stators on the shaft along with the HPC stages, then snapped the whole thing into the casing. It's not 180 deg, but the plastic should flex enough to allow it to go in.

I would just like to say thank you, we are printing one for a middle school who has a teacher trying to put together a makerspace.

Hello,
very nice and accurate model. I printed on Rebel IIb. Filament PLA, layer 0.2, nozzle 0.4. Sliced CURA with Supports and Slic4r Průša for parts with integrated supports.
Thank you very much.
Vladimir of Pilsen, Czech Republic

Hi!
First thank you for that great model.
I'm almost finished printing it (only the LPT stators left), and started assembling what could be, but I can't seem to be able to push fit the 6204 bearing on the LP shaft front. I've broken 3 already, trying to force it in place. Same for the smaller bearing on this shaft.
The other 2 bearings went on quite easily (had to use some percussive persuasion but they went on great).
My printer is calibrated, all parts fit together except those bearings.
What do you suggest? I was thinking about putting the bearings in the oven to heat them to something like 100°C, and then push fit them. But seems a bit overkill.
I printed the shaft in PLA.

Thank you!

I'm having the same issue. I tried sanding, but I worry about the wall thickness. Did you ever had luck with a solution to this?

Heat expands....cold shrinks. Put the bearings in your freezer for a few hours before you install them.

I am very new to to 3d printing and am having trouble with the fan stator housing,I used the one with supports,it collapsed I suspect between the stator supports and the hub, any suggestions? printer is a prusa i3 mk2
An excellent model by the way and very generous of CATIAV5FTW to make it available to anyone free of charge.

I'm trying to print the Nozzle_With_Supports using Cura 15.04.6 and a Printerbot Simple Metal. The .stl file shows that there are inverted T-shaped supports under each blade, set so that the flat part of the tee should start printing on layer one. The flat part of the tee never shows in layer view, and nothing support-wise shows until several layers in, where the vertical part of the tee starts to try to print in mid-air. Needless to say, it doesn't work. Anyone have any suggestions on how to get the supports to print properly?

IS there any exploded view for assembly purpose? Or any instructions for assembly?

No, aside from the diagrams in the pictures above. Someone made a video assembling it here: https://www.youtube.com/watch?v=5hD_ZGOuvJE&t=179s

Hello !
maybe someone can show me the difference between the HPC stage 4 and 5 ? i'm pretty sure I haven't swaped them but i prefer to be sure :) !
Thanks for the help.

Stage 5 is smaller than stage 4.

Hey, you guys are not using any support for example on HP_core_casing? All the casings have overhangs...

Supports on the regular overhangs are still required.

where are instruction to assembly this engine?

I don't have assembly instructions, but here's a video that someone made that shows the process: https://www.youtube.com/watch?v=5hD_ZGOuvJE&t=179s

Thank you very much !

Hello CATIAV5FTW,

I have just finished printing your assembly and wow, what can I say, absolutely gorgeous design work! I would like to post my pictures of this print on 3dHubs to attract customers along with other thingiverse prints. Could I get your permission to do so? I will of course give you full credit for design and modeling work on my hub page.

Thank you,
Andrey

Hi CATIAV5FTW
I am hoping to use this model as the basis for a nacelle we are designing, are there any complete or editable Catia V5 files available that we can modify to suit our dimensions. Currently we are looking at having to start form scratch modelling an engine. But our technology Is the nacelle
I am hoping to run the engine using an electric motor and get the nacelle working (Thrust reverse), we need a good starting point and this seems to be the best model for our needs.
I am not sure what the convention is on sharing this data though.

Thanks very much for those, I will share our modification to it when we are complete in Grab CAD, we are initially going to modify it to our geometry for a High Bypass flow engine.

Hello, I have issue with printing part "Nozzle_With_Supports.stl" . I printed it on my Prusa MK2S but I recently found out, that there are "missing" some layers in the printed model. I went through the whole model each layer in the Prusa Control and Slic3r and yes there are missing layers. Did someone have same issue? If there is someone who has working Gcode for this part for Pruska MK2 please let me know or if you could send me this I would really appreciate because I was not able to fix it (I tried to use Meshmixer but without any success). Thank you and happy printing :-) .

Here is screenshot example what I mean:
https://www.dropbox.com/s/93kyhy3zspan15k/Nozzle_With_Supports.png?dl=0

There is only support material and no part material. And in this part I have a lot of sections like this.

Here is real printed part:
https://www.dropbox.com/s/vqml5woqw0yklsh/IMG_1397.jpg?dl=0

UPDATE: It seems that Cura 2.6.2 is capable to create GCode in right way, but I was not able to print it however I set correct printer. It looked like that it ignored Z axis calibration. Any idea how to go on? :-/

Hi, are you still having issues with this part?

Hello, yes I have still issue with this part. :-(

Just wondering what you used to put together the screws in the more tight spaces. Just finished spray painting. Looking to finally assemble in the next couple weeks.

A lot of patience and some needlenose pliers as needed. I'd like to revise some of the screw placements someday...

It is now day 8 of my consecutive print. :) All the casings are done. All the low pressure shafts are done. High pressure shaft is printing. So far, so good. Stand and spinner are tomorrow, then the fans+turbines+stators marathon begins.

One thing I noticed is that the Low pressure shafts fore and aft should have notched ends, so when the model is assembled they are interlocked. I suspect most people glue them, but notched ends would be really handy if you ever need to dismantle the model in the future.

I'll definitely add that to the list of revisions I'll make someday. Notched ends are a very good idea and should've been done from the start.

Thanks for this model! I love jet engines, and your model is gorgeous! Notched ends on the shafts be super cool, and I am just starting my printing of this, so you have like 2 weeks before I print out the shafts. ;) Thanks!

Uploaded revised (Rev A) versions of the forward and aft LP shafts, as well as the connector. I changed it from round to hexagonal. Let me know if that works for you all.

Ansolutely agree. Notched or splined joint would be perfect.

First of all, great model to print. Also a good project to really "learn" how to print with all the different shapes and sizes in the parts. I am however struggling with the tapered casings. What's the best practice of ppl here with the supports for the top flanges?

I printed mine with the larger end on top so the flange supports have a more solid base instead of starting up from the casing.

I'm having difficulty identifying some of the parts in the photographs, so I'm not sure which color to print them (namely the Low Pressure Shaft because it's obstructed). Is there any way the colors could be added to the BOM or posted here in the comments?

I want to make sure this is done right the first time :)

Thanks.

I think the color of the low pressure shaft does not really matter because it is not really visible when the modelist assembled.
Mine is printed white :)

Regards

Well, actually, the front flange where it mounts to the fan and 1 cm or so on each side of the front bearing is visible.
Printed mine in black.

Thanks! I'll finish mine up in white as well, then.

Been printing with a Prusa MK2s since. I have some problem printing the fan_with_support though. For some reason, the printer keep on jamming on this particular print. Other prints are good and smooth, including the Combustion and HPT Casing.

Do you have any idea what could went wrong? Been troubleshooting since the problem arises. It's either the nozzle or the heatbreak jammed in the middle of the print.

Best looking jet engine model out there! Thanks for this beautiful model!!

It's not an easy part to print, but I haven't had any issues, and I haven't really heard much from anybody else. Is the filament actually jammed in the nozzle, or is the filament just ground down from the extruder gear due to too many retractions?

Yes, i have just solved it. I think it's the extruder gear issue, it has misaligned due to unknown reason. LOL.

It's a real beauty! Thanks for the design again! I will make it a gift to one of my student!

Don't know if this tip is of any use to the multitude of people printing this great model, but first time I tried to glue the flat strip into the nozzle I made a real mess of it. I was using Gorilla super glue, which did work, but I really struggled at the pointed end keeping the strip in place while the glue set and ended up (like I always do with super glue) sticking my fingers to the nozzle and it ended up with white blotches all over the black nozzle.

2nd attempt I tried to get the strip to maintain the spiral shape before gluing. So I laid the strip dry without glue in the groove and secured at both ends with masking tape. I did need to cut about 2 mm off one end for a good fit (not sure why). I then put the whole thing in very hot water (around 80 C) in a cup and left it until the water went cold. To my surprise the strip was perfectly in the groove, even when tape removed. After 5 days it was still perfectly in there, still no glue, however, as a precaution I have just put a dab of glue at both ends.

Hey mate.

Wow, what a fantastic great looking model. I am an Aeronautical Engineer student here in Australia and when I seen this model, I went and showed one of my lectures. As I was, he was just blown away on how great this model is. I have worked with CATIA "not my favourite" and Inventor "my favourite" and so I can really appreciate the amount of time and effort that would have went into this. So my lecturer and I will be making one. I will be starting my one as soon as semester break begins :).

So with that all said, I am going to be printing this on my Up Plus 2 printer and most likely going to be using PLA filament so that I will have minimal shrinkage/warping compared to ABS. I have a few questions with regards to the purchasing of the materials. Firstly, the 2.5mm DIA screws that you use. Would a 2mm DIA screw work instead? or even 3mm? or is it paramount that it be 2.5mm? Also, regarding the bearings. If I was to use the one type of bearing, say a 8mm ID, 22mm OD, 7mm W and fabricate components to fit the size difference. Would that work? or is it only suitable to use the bearings that you listed? Only asking as we already have these materials and saves purchasing additional ones.

Also, are all dimension for the STL files in mm or inch? So l make sure when l import the files in the program, l use the right dimensions.

Again, fantastic model. :)

Thank you

I'm glad you all like it. I'm sure the 2mm screws would be fine; they'd probably be a little loose, but it won't be an issue after you tighten them. The 3mm ones probably would not work since the holes aren't big enough. For the bearings, as long as they're sized such that the parts can fit through them without clashing, you can print whatever adaptors necessary to make them fit. I picked my bearings because they fit well with the scale of the engine and were readily available on the internet. And the parts are in mm. Looking forward to seeing it printed!

Hey

With regards to your FAN file cut in 3. The file says that they have supports but when I load them they don't have the supports. Are you able to update those files with the supports please.

Also, is there any chance you could upload the Fan Stator Casing and Support (with supports) into 3 parts? Its just the second parts just exceeds the print volume on my Up Plus 2.

Thank you

Just fixed and reuploaded the fan cut in thirds. I'll section the fan stator casing and upload when I get the chance.

Awesome, thank you very much

Hi,

first of all great model!

I am a bit confused regarding the fan cut in 3 parts. The Name is "... with supports" but in Thingiview the 3 files are shown without supports?
Is this a failure from Thingiview or are there no supports?
And is there are really no supports.. Could you maybe upload These files with supports?

Many thanks for your help! :)

That's correct, it should've had supports, but they weren't included for some reason. I fixed the files and reuploaded them with the same names.

Thanks a lot!

I'll upload a "made" as soon as ist done :)

Comments deleted.

Hi, I just love this model.
I am currently printing one off an an original Prusa Mk2S. However, I am having a bit of difficulty with the Fan_Stator_Casing_and_Support_With_Supports.
In general for all the casing parts I am using the files with supports, if available, but I assume you still need to use supports for the flange on top that bolts to the next casing item.

But what I am struggling with is the custom supports on the Fan_Stator_Casing_and_Support_With_Supports.
Whilst they are just the same as on the rotor parts, except bigger and higher, they seem very thin and each time I try to print some of the supports just collapse before they can even be used as supports (i.e whilst at a level the supports are still being built). Each time it is different supports that fail. In actual fact if I slice with Simplyify3D it does not even see the uprights of the supports, only the bits on the build surface. I assume it is something I am doing wrong as I am fairly new to 3D printing. Can anybody offer advice how to thicken the custom supports ?
So far only used free version of sketchup for models so don't think I can change the supplied files with this.

Steve

Correct, you need to add regular supports for the flanges. What's your nozzle diameter? The custom supports are .4 mm thick, so you should make sure that your Extrusion Width is set to .4 mm.

Very grateful for quick reply.
My nozzle is 0.4 mm and up till now have been leaving the extrusion width at the Auto.
Just tried to slice with Simplify3D and the supports are now visible in preview so assume they are much thicker than before.
Many thanks for the advice :-)

Steve

Just ... Beautiful!

When I go to slice the Fan_-_Cut_1_of_3_With_Supports files (all 3 of them) slic3r shows that those cuts are only 1.35m x 5.57m x 3.51m big. I know that's not supposed to be the case. Is Slic3r reading the file wrong and I need to scale up? If so how much do I scale up to make it match. I haven't noticed any other issues with the size of the projects on other files.

I'm guessing it's a mm vs. inch scaling factor.

Is that something I can change? I've sliced in both CURA and Slic3r now and they generate the same small g-codes. Small size, very little filament used etc

Yeah, just find where the scaling option is in the slicer and scale up by 2540%. However, I fixed the files just now so the scaling is correct. You should redownload the 3 fan cut files and use those.

Awesome, thank you!

Using Simplify3D and a FlashForge Finder I cannot print the Fan_-_Cut_X_of_3_With_Supports files. The non-manifold cut ends do not stitch sanely with S3D no matter the settings choices. Can you please make the chopped files manifold for us small-printered peasants?

I repaired 1/3 via MeshMixer, but there is 1 face on each of 2/3 and 3/3 which does not repair correctly. @CATIAV5FTW can you address this? Also these files are lacking the custom supports despite the filename indicating they are there :-(

I just fixed the cut files by adjusting the section cut a bit, adding back the supports, and scaling up so the stl is in mm. Let me know if these files are still non-manifold. I reuploaded the files under the same names.

The fans look great! Thank you very much for fixing them! <3

I've added one costum support to the combustion lining on the huge overhang. If you'd like to have it, i can send you the stl file and you can add it to your download files. ;) (I'm currently printing this in my Prusa i3 Mk2 and it works great!!)

@MisterHomer I'd be interested in this. I assume it's better than printing Simplify's support towers all around the perimeter.

Here you can find the Combustion lining with other Supports. You wont need any other Supports. https://www.thingiverse.com/thing:2462450

3D printable Jet Engine - Combustion Lining

It worked really well for me.

I just tried that stl for the combustion liner, and it did not come out good at all on my Anet A8.
What did work perfectly was to use the original stl and set Supports to Everywhere, and overhang to 80 deg in Cura. That resulted in a perfect support ring for just that section, and nowhere else.

Would it be possible to get the Fan Stator Casing and Support (unsectioned) cut in thirds or quarters to fit on smaller beds? I'm only 200mm x 200mm. Thanks.

Hi CAT, It is indeed a very nice design. Many thanks. Having worked in the industry and seen so many engines getting produced in real life, could not believe that such a nice design could be done by printing. Couple of points on the files. There seems to be a small mismatch on the Fan Stator which has an extra segment as compared to the casing and the HPC casings Perhaps this is because you need to fit the bearing in the cut section assembly. Also on the Fan there are a few extra files in cut in 3 parts and they seem to be reduced in size or are they used somewhere. My printing is almost done and expect to assemble over the weekend....

I have read most of the comments and details for this wonderful project but can't see anywhere what material is used.
Can this be built with PLA?
Does anyone know if I can print this a full scale on Prusa 3i Mk2S?
Can't wait to start!
Paul

Yep, PLA worked for me. I made it full scale on my Prusa i3 mk2s.

Were you able to print the fan blades without support on the MK2S? They look like they should be fine, but Slic3r keeps adding support despite my threshold being at 80 degrees. Just curious whether I should follow my intuition or let Slic3r do its thing.

EDIT: I just found the Fan_with_supports file and it confirms my suspicion. The blades should print nicely at .1mm without additional support. Sorry for bothering you!

Yep, no additional supports needed. Worked perfectly the first time.

Thanks very much for the reply. I noticed that when I brought the fan STL into the Prusa 3d slicer software it was vertical.
I assume that it is best to print it flat?
Paul

You'll find that the files don't often import into Slic3r in the correct orientation. Always try to get the big flat side facing down. There are also a bunch of images included with the downloaded where he shows the proper orientation for printing some of the parts.

Sorry for late reply, but thanks for the information.
Just off on holiday for a while so will start this project mid July.

So far this print has been an absolute delight! Very much appreciate all the work you've put in. I'm about to tackle the Combustion Lining, and I wish there were supports built in for the massive overhang near the front of the piece. Cura adds supports, but it adds them throughout the piece, not just where it's really needed.

How are people printing the casings? I'm really struggling to clean the supports up

You are an extremely talented designer.We printed this model at 175% scale and everything fit together so intuitively. Really great work on the model and we aren't joking when we say it's one of the best models we have ever printed. We made custom bearings, out of 608's and 624's, since the scale was so large. They came out great and the model spins easily.

We have been sharing your name on all our posts so hopefully it drove a few people here. Thanks again for the model.

Check out the IG videos here:
https://www.instagram.com/p/BTugv-HFYFe/?taken-by=gcreate3d

and here:

https://www.instagram.com/p/BTuhosmlNam/?taken-by=gcreate3d

if you have Instagram or Facebook we would love to edit our posts to show it. We couldn't find one.

Do it really need 'open' bearings? I have a bunch of closed types if they would be suitable?

Open bearings just spin more freely.

Actually, Shielded bearings with light oil would spin just as free. There is no contact between the inner race of the bearing and the shield.
The shield will act as a dust cover and help keep debris out of the bearings.

I'm sure closed bearings would be fine. I would recommend using bearings with shields, not rubber seals. The seals may cause too much drag. I would also recommend using bearings that have an oil lubrication, not grease. this will allow the bearings to free spin without resistance. I'm about 65% finished with the prints for this model. I'm looking forward to the assembly.

This looks beautiful but i'm having issues with the main fan.

Fan_-_Cut_1_of_3_With_Supports = has mesh issues and won't slice properly
Fan_half = low resolution mesh

Hi!

First off - thank you for making such a gorgeous model available to all of us for the price of a spool of filament and some hours of our time!

I've been trying to figure out a way to print the combustion liner, but that lip on the forward end is throwing me off. Would it be possible to design a support and integrate it into the file between the liner and the lip? Slic3r isn't generating support in there.

Really great design. I'm fairly new to 3D printing. I have a Prusa MK2S and started printing a few parts yesterday. Is there a file for the assembly. This looks a bit complex and directions would be helpful.

Don't have full assembly instructions, but I did upload cross-section views with the parts labeled, as well as the parts list excel file. Hope that helps.

Sorry, I have one more question. What Layer height did you use and fill%. I am having issues with the supports for the LPT Casing. The Supports are not printing on the upper part of the print.

Thank you for your reply. I now see the cross section that you labeled. This will be very helpful.

Hi , thank you for sharing this awesome design , how long it will take to print and what is max length dimension of the engine that I can to print , my printer build area is 500,400,500 mm

Depends on how many parts you print at a time. That's a giant print area, so these parts will be no problem. Everything is under 250 mm.

Would it be alright with you if I have a printing service print this for me? Unfortunately, I don't have access to a good printer and this is the best model of a turbofan that I can find.

Yes, absolutely alright. I'd love to see it after it's printed too.

I have tried to print the UM3 Stator Casing and support cut in half part 2 twice. Each time the print shifts over about 1/4 of an inch half way through printing. Did anybody else have this issue?

I haven't heard of anybody having that issue. Have you been able to resolve it?

This is an absolutely beautiful design. I can't wait to get started on it. However, I have one question: how tight are any of the tolerance for pieces that fit together? Every time I try to print something that assembles, the pieces never fit together without some sanding and filing. Would I run into any issues with this? Or should I take the time to really dial my printer in first.

The clearances are pretty tight towards the turbine, so I'd recommend making sure your printer is in top form. Also, be sure your x y z axes are actually perpendicular. Mine weren't, so the engine wobbles as it spins.

Spent the night dialing my printer in and im fairly confident in it. Can't wait to start on this model tomorrow!

awesome! thanks for the quick reply!!

last question, how much material do you need to print this beast? :D (i will print unsectioned)

Not sure, but I'd guess roughly a kilogram

I think it's going to be higher than 1kg. Just the housing and LP/HP shafts weigh in at around 600 grams of PLA for me, and that doesn't include the probably 220g of support material (some of it was unnecessary in hindsight).

I suspect I'll be pushing around 2kg once all the fan/turbines/stators are printed.

After all is said and done, my final model (mostly PLA with some PET for the stand and LP/HP fans) weights in at 1290g, including screws and bearings.

Ooooooooke ......... I'm new at this printing stuff and found the beast to begin . My daughter who works in the industry will love this engine . She will put it up together .... s'been her job for the past 6 years . Can't beleive i am going to try to give her that for Christmas . A great BIG THANKS for the files ( hoping to get true this before Christmas and with no big problems ) .

Thanks again for your time doing this great model .

P.S. I work with 3DSMax and can't figure out how to get my stl exported without problems or errors . I'm new to 3D printing not with Max but will find a way some day i hope . Can't wait to print my stuff .

You're welcome! I'm looking forward to seeing it, and feel free to PM me for any issues. Finishing by Christmas is very feasible. I'm afraid I can't help you with 3DSmax... Never used it before.

Sorry if this has been asked before, but I know the original size is too big for my printer, but if I scale every part the same it should still come out correct?

I am dying to do this.

Yes, just make sure you can find ball bearings to match that smaller scale.

hi sir, what temperature did you put in this print? did you add any special setting?

Using Hatchbox PLA, I printed around 190 C. What kind of special settings do you have in mind?

maybe linear infill or something like raft size

Infill shouldn't matter too much, linear would be fine. I haven't used rafts for mine, but a 10 mm raft may be good to eliminate warping if that's an issue for you.

Hello, thank you for uploading all the files, did you test it with an electric engine?

I haven't, but I think others have.

What program was used to make this

how long does the entire print take and do you think that it would print well on a monoprice mp select mini?

yea i would like to know if everything fits because i have the same printer and just looking through the parts to see if i can do it.

The print duration depends on your print settings and how many parts you print at a time. To maximize print quality, I print slow and only a few parts at a time, so it took probably 200 hrs or so. That's a small printer, but it may be possible. I'll PM you details.

Hey CAT, this looks like an awesome engine. I'm new to this stuff so please don't mind the foolish questions. I have an sPro 60 printer @ work and uses SLS. Would that be fine for something like this do you know? Mainly used for shoe prototypes so I'm not sure. It can print nylon as well as TPU.

I don't see why not! I'd really like to see this printed on an SLS setup.

It's been a while but almost nearly there. In the process of spray painting! Hopefully we can ramp up the process and be completed in the next few weeks!

Comments deleted.

What software do you use. I'm having trouble finding a reliable software where I can fully allow my creative juices to flow.

how did people go about breaking away the supports on pieces like "HPC stage 1 stator with supports". Im finding it very hard to break them away under each blade

The ease of breaking away the supports ultimately depends on the printer settings. I would think that overextruding would a main factor in why the supports are hard to remove.

sto facendo questa turbina per gli esami di stato ma ho un grande problema che non so del tutto quanti pezzi sono totali togliendo i cuscinetti e viti voglio farla uguale al disegno . per una parte sezionata. AIUTO . UGUALE UGUALE ALLA FOTO

The list of what parts to print and how many of each are contained in the BOM.xlsx file at the bottom of the files list.

Hi CATIAV5FTW

I have started to print the parts of the engine using a Wanhao Duplicator i3. So far I have printed the fan, spinner and the fan casing in two parts. All these parts printed well using the default medium print quality setting in CURA. (The fan took 51 hours to print) I am having problems with the fan stator. The custom supports for the trailing edges of the blades separate from the raft every time after about the third layer is being put down. I have tried to print this part at both medium and high quality and at high quality but with the print temperature reduced from 195C to 185C.

Any ideas about what I should look at to improve the situation?

(Many thanks for your work on this design, although not a triple-spool it reminds me very much an early RB211i saw at the Filton airshow back in the 1970s)

Bob

Are the tabbed rafts on each support lifting from the raft of the whole part, or are the thin support walls lifting from the tabbed raft for each support themselves?

Hi CATOAV5FTW

Being relatively new to three-D printing I am unsure about what you mean by the term 'tabbed raft' . The parts that separate from the raft are about 30 mm lengths of plastic less than 1 mm thick. I have tried using a different filament on Friday and achieved a better print but still with some problems caused by supports separating from the raft. I was considering opening the parts in a drawing package and adding a broader base to the custom supports.

Post script

I have been looking at the STEP files using Autodesk Inventor, I can now understand the 'tabbed rafts'. I measured the thickness of these rafts and found it to be 0.105 mm I wonder if my printer is unable to resolve this fine detail and that explains why I have not seen the rafts and why the custom supports are separating from the rafts laid down by the CURA software's default setup.

Many thanks

Bob

The fan was intended to be printed at .1mm layer height, so I made them a tiny bit thicker to ensure my slicer (Simplify3D) would recognize them. Did you try a .1mm layer height?

Hey CATIAV5FTW, I am working on printing the fan with the three part files, but when I open them in either a slicer or an STL viewer, the model is only a few millimeters in each dimension, much smaller than it should be. Do you know of any issues with these files, or can I chalk this up to my system? Thanks.

I must've saved the files when my CATIA was set to inches. Just scale up the parts by 25.4 and you're set.

Thanks so much! Looking forward to getting this model printed and built!

Thanks for the design. One question: Have you printed the fan with custom support without additional normal supports?
Thx

Yes, no additional supports are needed.

Hi CATIAV5FTW, have thought to add a Nacelle to this model? I would be superb!

I did briefly, but no plans currently

This is an amazing model.....have you think to go and make a turboshaft? or a turboprop model?

Hi CATIAV5FTW, Thanks for the design this is a really good model, I am planning on printing this soon, I cannot find the assembly diagram in your files though, do you know where it is ?

The cross section view with the parts labeled is there as a picture

Ah OK got it thanks,

Comments deleted.

Hello,

Quick question: did you print these with infills? If so, what do you recommend?

Best regards!

15-30% is fine.

Good afternoon.
I am interested in buying the rights to your model if possible to sell a printed turbine engine to my school. Would you be willing to allow me to do that? If so we can talk more privately I just don't know how to send you my email in a private message.

The combustion lining with supports appears to have a massive overhang if I print it with the Aft face down. How do I print that segment without adding supports?

If you're referring to how the forward part kind of loops back to create the overhang, that area will need supports. That's the only area that needs supports for that part.

Would it be possible to upload the fan in three parts? My print area is big enough to print everything but the fan halves. Thank you for designing this engine!

Added:
Fan - Cut 1 of 3 (With Supports).stl
Fan - Cut 2 of 3 (With Supports).stl
Fan - Cut 3 of 3 (With Supports).stl

I cannot tell you how happy I am! These fit my print area marvelously. You are awesome.

Thank you so much!!!!!!!!!!!

Hello! Thank you for designing this engine. This is by far the coolest print on the whole site! I printed one in 60% scale and it was fantastic. I showed it to my Gas Turbine Engines professor and he was absolutely thrilled. I'm now printing it in 100% scale and I have the print area to print every part but the fan. The fan halves are just slightly too big for me to print. Would it be possible to upload the fan in thirds or quarters? I would really appreciate it! Once again thank you for all of the hard work you put into this design!

Hi Chris great work, I have printed two of these now. I work in aviation so one for home and one for the office. I am very happy with everything except the turbine blades. No matter what i try I can't get clean trailing edges to the turbine blades. With the rest looking so good this detracts from the finish. Supports (the included ones ) or Simplify produced ones always tear off bits of the trailing edge. Now I've seen some real turbines look like that but I'm not looking for the trash chic look. I have tried 4 printers, 4 different brands of PLA. A multitude of settings, got some ideas?

It hasn't been a problem for me. What layer height and nozzle diameter do you use?

I've tied 0.15, 0.2, 0.25, with .35 and 0.4mm nozzles. I've tried various extrusion widths and multipliers. Temps between 195 and 220degC. Changed speeds. In all cases the support will pull off some of the trailing edge on all or most of the blades. The rest has printed very well. Actually the only common things are the .stl file and Simplify. Might try another slicer.

What about your extrusion multiplier? I'm thinking if you're slightly overextruding, there's too much plastic forced down onto the support, making it hard to remove without damage.

Will start another set of prints very soon and let you know.

With some PLA, tried 0.7, 0.8 for extrusion multipliers. Still the same result for the trailing edges, but was worse as it caused other issues, this is on a printer I use for high detail that prints very well (usually). Have also tried 100% cooling as well.
What brand/colour filament do you use? I might move the support discs away from the turbines a touch and try that.

How are the turbine rotors looking?

Hi, I've printed another dozen with various settings based on extrusion on different printers but same the issue. All LPT 4 with supports. The step in the support disc is where 90% of the adhesions have been.

However Iast print I tried the Separate Connected Surfaces function in S3D. Then I could select the support disc and lower it 0.1mm. That time the disc didn't stick the blade trailing edges. So a bit more testing with the other rotors and some fresh filament to go.

I now have the rotating parts printed and assembled. I bought S3D and all is going well. I will post some photos in Made.

I am trying to print the turbine parts on a davinci jr 1.0W and have run into a part that will not print? the LPT Spool will slice and appear to download. The computer will say download successful, but the printer locks up in "downloading from USB" mode. I have printed many of the other parts with out problem. I have tried re-downloading the zipped files and extracting the spool again, with no difference in the problem. I have tried both XYZ maker and XYZware to print the spool. Same problem . With XYZware, I do get a printer error pop-up message.

The part is within the 5.9x5.9 limits of the printer.

Is there a place to download individual files that are not zipped?

I am not sure how to proceed?

I have made the executive decision to opt for different software. I saw Simplify3D mentioned in the comments, and I have purchased it.
The part that would not print with XYZmaker or XYZware, prints fine with Simplify3D. It is not cheap, but since I teach at a college, I earned a 25% discount. This software is head and shoulders above the XYZ software. If you are using a 3D printer as more than a passing fancy, I recommend getting Simplify3D. As in other aspects of life, if you have better tools, your work will turn out better.

It now looks like I have a clear path to completion. The XYZ software also refused to print half of the stand?

You can download the parts individually if you go through the Thing Files tab and find the specific part. By the way, I also have S3D, and yes, it's expensive. But it's truly a case of getting what you pay for, and I'm glad it's working well for you too.

maybe make one with the housing going all the way around so it can be a working model

Hello, great thing!

But I have a problem... my slicer (I am using Repetier and Slic3r) report to me file Fan_Stator_Casing as non manifold.
Where could be a mistake? In my soft? Or in this file...?

Thank you, Roman

This is the first time hearing about that error on that part. I use simplify3d and I haven't had any issues. I'm guessing your slicer doesn't like how the stator blade supports intersect the stator blades.

Is there any way to print this on a daVinci Jr.1.0W ? Print area is 5.9 x 5.9 x 5.9 inches. I do not want to look for other bearings. I guess I could cut away more of the housing, but I like the current look.
It looks like the half fan will not fit.

im making it with a flashforge finder, same size.
Just had to cut the main fan blades into 4 pieces.
and a minor cut on the Fan Stator Casing.
the rest is no problem.

Thanks for the response. I work at a Aviation Technician School and the engine would be a great demo piece.

That would leave two bolts per section. Are you super gluing the pieces together, or are you just using the hardware.

I have not glued any parts yet, Waiting for all the bolts from ebay. but im going to paint the model anyways, so im planning to glue them.

Seems like most of us work in aviation then :D

What software are you using to cut the fan model in half. I have just been using xyzmaker , but it does not seem to be up to the task.

All of the tutorials I have found for cutting objects do not deal with the situation of overlapping fan blades. Could you suggest a link?

Are the quarter fan models available on line?

Thanks

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great engine how did you do the back nozzle and what cad program did you use

The exhaust mixer back there was deceptively simple to model, and I use CATIA V5, hence my username. I actually made a tutorial on it a while back here: https://grabcad.com/tutorials/how-to-create-a-turbofan-exhaust-mixer-in-catia-v5

Hi, awsome project!
have you concidered making the engine housing?

I have considered but haven't modeled it up yet.

very nice model anyways! i hope you make the engine housing some day.

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hello
has ever anyone printed the bearings also by itself? i saw some projects about this and i am wondering if it could apply here too.
thx

Didnt see it in the comments yet, but: how heavy is it? (how much filament is used?)

Im planning to print a model for a friend of mine and for myself, were both aerospace engineers, so we would love to have this! :D

Not sure, but I'd wager somewhere around 1 kg. That would depend on your infill settings though.

how many parts need to be glued together? if any...

The low pressure turbine rotors need to be glued to the low pressure turbine spool, and the spinner stripe needs to be glued to the spinner. Everything else can stay as a friction-fit.

Hello CatiaV5FTW I was wondering if you could send the stp files for all the parts. I know this is a lot ot ask but this would greatly help my science fair project. Thank you for time and hope you are enjoying your holidays.

Comments deleted.

Step files are contained in No_Supports_STEP.zip.

Hello CatiaV5FTW I was wondering if you could send the stp files for all the parts. I know this is a lot ot ask but this would greatly help my science fair project. Thank you for time and hope you are enjoying your holidays.

Hello CatiaV5FTW I was wondering if you could send the stp files for all the parts. I know this is a lot ot ask but this would greatly help my science fair project. Thank you for time and hope you are enjoying your holidays.

Hello CatiaV5FTW I was wondering if you could send the stp files for all the parts. I know this is a lot ot ask but this would greatly help my science fair project. Thank you for time and hope you are enjoying your holidays.

Amazing, design, just posted my make on this. Totally rewarding to see it finished, thanks @CATIAV5FTW

Awesome where can I get jet fuel?

What's the sequency for assembling shaft? Should I assembly the shaft inside the body? Because If I assembly outside, I can't fit on the body by laterral 'cut' of body :(
Also, where "Swirl Dome Plate" goes?

You should first assemble the complete spool (HP Compressor stages 1-5 and Stators 1-4) then you slide it in from the front to back and the stators should snap in their place and the spool should turn freely.

The swirl plate is where the fuel injectors meet the combustion chamber, in the combustion lining you should see two little tabs that match perfectly the shape of the plate and it slides in place like a glove, you should put each injector in the small holes it have.

By shaft, do you mean the high-pressure shaft? You have to assemble the spool, compressor blades, and stators all together, then snap it into the HP casing. It's kind of hard to describe, sorry.
The swirl dome plate goes in the combustion lining. It's shown in red in the colorful cross-section picture.

Hi, there is no difference between the combustion lining with and without supports, none of them have supports, could you upload this piece with custom supports ?
Thank you :)

The custom supports are on the trailing edges of the stator blades at the back of the combustion lining. That's the only difference.

Awsome!
Im planing on starting to print this. Already bought all mechanical parts i need.
Id like to use grey as well. Can u tell me which filement u are using? I am afraid to get a too light/dark grey.

Comments deleted.

I used Hatchbox PLA in the silver color.

How big is this engine?
how tall and how Long is it? :)

The fan casing diameter is around 8 inches, and total length is 14 inches, if I remember correctly.

Any news on assembly guide? Ate least assembly sequency would help a lot.
Tks!

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Hi CATIA5FTW,
I have been so fascinated of your model , that I had to do it,
now I finished it with some changes by picture of real one / 18 blades fan with opposite direction + coloured leading edge, new spinner and nacelle , I hope will be liked
regards,
Karol

Hey,

how can I get the STL. files to print your awesome Jet engine?

Best reguards
Robin

Or which Programm I Need to open this Files.

Sorry for my Problems but i would like to print this Thing it is so awesome great job

The stl files are in the "Thing Files" section. The files can be opened in the slicing program you use to print files.

Jeah tanks I found it. How long did you print the whole Thing?
The Fan with Support takes 2 days and 9 hours^^

It took a couple weeks I think. The wait was definitely worth it.

I am not an engineer or anything. My son is autistic and likes to learn how things work he is 4 but I am excited to expose him to as much as I can. I am somewhat mechanical (I rebuilt an automatic transmission). Am I capable/would it be worth buying a 3d printer just to make this and other things as he gets older? How much $ in plastic do you have in this? I understand Makergear m2 printer is about $1800. If I don't get one, would you print me one and sell to me? Thank you!!