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3D Printable Jet Engine

by CATIAV5FTW, published

3D Printable Jet Engine by CATIAV5FTW Feb 9, 2016

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209920Views 70782Downloads 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 any 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!

How I Designed This

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

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21 hours ago - Modified 21 hours ago

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.

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'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!!)

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.

May 29, 2017 - Modified May 29, 2017

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.

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.

May 6, 2017 - Modified May 6, 2017
spdsk8er2 - in reply to CATIAV5FTW

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.

Apr 24, 2017 - Modified Apr 24, 2017

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

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.

Absolutely. It'll be a couple weeks since we're running different plastics but once we get to nylon we should be good to print. I'll absolutely post once it's finished.

Mar 12, 2017 - Modified Mar 12, 2017

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

I use CATIA

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.

Mar 6, 2017 - Modified Mar 6, 2017

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?

Mar 5, 2017 - Modified Mar 5, 2017
Equipoisebob - in reply to CATIAV5FTW

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.

Jan 24, 2017 - Modified Jan 25, 2017

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.

Jan 13, 2017 - Modified Jan 13, 2017

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

Jan 14, 2017 - Modified Jan 14, 2017
pershina - in reply to perand65

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

Comments deleted.

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.

Comments deleted.

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!

Comments deleted.

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!!

Hi jlogsdon88,
We would be happy to print this and send it to you, if you like, send an email to us at [email protected] and we can organize the details.
Regards,
Ethan Brown

I just ordered the screws, nuts, fastners, and ball bearings; I finally finishing this massive awesome print.

For some reason the holes in the fan stator don't align with the holes for the compressor some of them do but others don't. I have made sure I printed parts 1 and 2 of the fan stator - is this a known problem ?

I'm guessing the interface between the two halves of the fan stator casing needs some sanding. Either that or there's some uneven rates of shrinkage between those parts. I checked those files just now, and the holes line up. Could you send me a picture of the problem?

Hi. Just to be sure: parts like "Low Pressure Shaft Aft" needs a custom support (from slicer program), right? Since there's no 'support' version.

Yes, unlabeled parts like that need regular supports.

Tks!
I'm about 65% done of all parts :)

This a realy great pice of art. Thanks a lot for sharing.
I am already printig one myself. Since we have other packaging lots here in Germany, I was looking for the total number of all screws. Unfortunately, they are not in the parts list. On the basis of the pictures I counted 69. I hope this is correct.

You are close, there is another set of 8 screws, bringing the total to 77. So you'll need 77 screws, 77 nuts, and 146 washers. The nuts on the fan seat directly into the fan itself, so those 8 nuts don't need washers; thus, 146 washers instead of 154.

Three pieces down, way too many to go, I'm so excited to get this thing finished. Have you given any consideration into turning this into a working model with perhaps something like compressed air?

No plans right now, I was just happy with a free-spinning model. If I get bored with it, I might consider it. Just be sure that your printer axes are as perpendicular as you can get them, because the rotors will wobble and scrape against the casings if the axes are off by even .5 deg. Learned this the hard way.

How can i test that before I move forward?

I put a carpenter's square on the build plate and lined it up to the z axis rods. I also printed a wide, circular test part with a cylindrical shaft and put the ball bearings for this engine on either end. This basically simulated an engine spool and rotor. Before I took the part off the build plate, I marked how it was oriented on the build plate. I spun this part and checked how it wobbled and adjusted the axes accordingly.

Comments deleted.

Maybe a stupid question: Do I need to print all the files to build this?

Parts list is now uploaded as a picture and as an Excel sheet.

No, there are some parts that I added custom supports to; these have "_with_supports" on the filename. I also uploaded the same parts without these custom supports; these have "_no_supports" on the filename. I recommend printing with the custom supports. There are also parts that don't require any custom supports (Spinner_Tip, for example). This sounds pretty confusing, so I'll try to put together a parts list over the weekend.

Is there any way I can find out how to put all the parts together?

I started putting together some directions earlier but I quit because it seemed like people were assembling it without any directions. It is a tricky process because of all the nested parts, so I can keep upload directions at some point.

Thanks man, for an awesome model ..! I had to give you some credits for this... My printers are going 24/7 to make the parts.
I used to work as an aircraft mechanic, and enjoy to see the basics again.

Keep ut the good work ! And thanks again for sharing...!

Regards,

Kjetil

Can't wait to see your model once you finish. I hope it turns out well for you!

Nov 9, 2016 - Modified Nov 9, 2016

Thank you a lot for your brilliant model.

This Model is awsome.
I just have a suggestion regarding the cut in half stand. You could put in a dovetail groove in order to make the pieces hold without glue.
On my printed version the connector has about 2 mm space in X and Y direction and is therefore not very useful.

Thanks for the feedback. I did think about making an interlocking joint, but I ended up keeping the joint as minimal as possible (to a straight line) and the intent is for it to just be glued using the connecting block.

Hey CATIAV5FTW,

Love the look of this thing. Nearly finished printing all my parts :D.
I had to use the cut in half STLs as my printer isn't large enough for the bigger parts. The "Stand_-_Cut_inHalf-_Part_1.stl" part seems to have a missing face and won't slice properly. When I slice it in simplify3d it slices as two separate parts - split in two up the vertical column.
The full size stand slices as a single part correctly, so it's just a problem with Part1 of the cut in half model.
Could you verify the mesh?

Much appreciated,
Blaise

That's interesting. I just tried it on my installation of Simplify3D and I had no issues. Everything looked fine. But that was slicing the STL that I saved on my computer. I then downloaded the file (the same file, theoretically) from here and tried that.... and I encountered the same problem as you. So then I retried the first file, and now that's having the same problem too! Weird. I remeshed the original file and now it works fine for real. I uploaded it with the same name and the file size is incidentally a lot smaller.

Thanks dude that did the trick. I've uploaded some pictures of my print!

CATIAV5FTW, how did you fix the rings on the shaft? did you use glue?

Yes, I used gorilla glue.

Is there a list of the parts that I need to print? I'm planning on making this, but I'm confused about what parts and how many parts I need.

Parts list is now uploaded as a picture and as an Excel sheet.

Comments deleted.

Hey CATIAV5FTW,
first, your Project is awsome! ;)
My questsion: Is it possible to get a part list. I´m not sure how many parts i need of a kind.
Thanks a lot!

Parts list is now uploaded as a picture and as an Excel sheet.

Every piece only once, except of the injection nozzle you have to print eleven times

Thanks that helps a ton

Oct 24, 2016 - Modified Oct 24, 2016

Awesome model and is coming along quite well. How were you able to print you parts and prevent stringing? Your model seems so polished and there seems to be no visible stringing from the overhang. Is there any way you printed the files? Also how would you go about polishing and refining the print? Thank you for your time!!!

Oct 27, 2016 - Modified Oct 27, 2016
CATIAV5FTW - in reply to Krithik_Ramesh

There's just a bit of stringing, but I kept it go a minimum by setting my retraction to at least 2.5 mm. I also set my filament coast distance (or what makerbot calls ooze) to .08 mm, and filament restart distance to -.07 mm. Are your settings somewhat similar to this? I also print at 185C, but that temp of course would vary between printers. Printing as low temp as possible and having plenty of retraction are the best ways to reduce stringing, in my opinion. I didn't do anything to polish the parts. Too much work!

Any way to get a model sized for a flashforge finder?

Most likely not. Scaling down the model would result in several parts being too thin to print, and there probably wouldn't be proper-sized bearings for it.

Thanks for the reply and thanks for making model available. Maybe one day I'll have a machine big enough to print one.

Amazing project!! i started to print parts but i have a problem to assemble Flat_Stripe on Spinner_Cone...
Flat_Strip is too long of ~5mm
how to doing to assemble Flat_strip without cutting this? you haven't problem with this parts?

(My printer calibration : X,Y,Z,E is good!)

My Flat Stripe also came out approx 5 or 6 mm too long but I dipped it in almost-boiling water (not sure the exact temp) for 1 second and it shrank slightly length-wise and is now a perfect fit.

My stripe was actually short by about 1mm. I would just recommend cutting the stripe. I don't think anyone would notice, honestly.

Just an idea, but do you suppose this could work as a functional model of a turbofan engine if machined in titanium and inconel?

I posted the full unsectioned parts - it's the last item in the file list. They do have my supports on them though. I imagine you'd want the files without them for machining. The bigger question though of whether it can work as an engine: maybe, but likely not. The combustion chamber design for turbine engines is very tricky, and considerable design work would be needed to make this work.

I'm no machinist; yet. But maybe the combustion chamber could be investment cast and the stator on it machined. Again, this is just an idea.

I think the fact that only 60% of the external body is there, you may have issues.

In your readme file you're saying follow the instructions in the Right order whem assembling the engine. That instructions file comes as a STG file. What Program can open such file? Or do you have the instructions also in other formats? Thanks for your advise!

Are you referring to the first item in the "Thing Files" list? It's a zip file with PNG images. Is it showing up as STG for you?

hello, i'd like to know how is the name of this engine thank you so much.

It's not based on any existing engine, but the fan is roughly similar in appearance to a Rolls-Royce Trent series fan.

I calculated all my gcodes files and came up with some interesting numbers. I posted them on my made post if anyone is interested.

Can you pleas post this whole assembly as one STL file I would like to print it all at once :) Thank you

I appreciate your ambition, but printing this all at once wouldn't be possible. Well, I guess you could, but it wouldn't spin and the supports would be unremovable in spots. I highly recommend printing the parts separately!

Thanks for the quick response. I am using PVA water soluble support material so as long as the water can get to them the supports will dissolve. I would still really like to try but totally understand why it is up in pieces it is a very complex part. If you change your mind feel free to message me and we can talk. Do you know of any other fully assemblies I could print?

There are a few other jet engine models floating around in Thingiverse that are simpler. I just wanted something more detailed so I made my own. In my opinion though, I think trying to print in one run would be more trouble than it's worth.

Just brilliant. Awesome!

about how long does it take to print the whole thing?

Not sure, I didn't keep track, and it depends on: (a) how many parts you want to print at a time, (b) layer height, (c) printing speed. I printing most parts one at a time, at .15mm or .1mm layer height, and 10mm/s perimeters, all in order to maximize surface quality. Maybe 150-175 hrs?

How many fuel injectors need to be printed? Thanks!

11, but I recommend printing extra in case one or more of them doesn't turn out so well.

Sep 19, 2016 - Modified Sep 19, 2016

Hello CATIAV5FTW,

  My name is Krithik Ramesh and I love aviation. My science fair project last year was "Redesigning the Jet Engine to be Impervious to Foreign Contaminants". I won Best in Show at the Denver Metro Regional Science Fair and placed in my division at Colorado State Science Fair and was nominated for nationals. This year I wanted to improve my project so, I wanted to create a working jet engine so I was wondering what kind of motor you used on your model.  I was also wondering what files you used to print yours (I noticed you gave more than one type of file for some parts). This would help me greatly and hopefully I will do better at science fair this year. I am also wondering if my 3d printer can fit all the parts and print them I have a Robo R1+Plus. Thank you for your time. P.S. Excellent Model it is soo cool ! :)

Krithik

Thank you soo much that was very helpful!!!

This model doesn't have a motor inside. It's just a free-spinning model that you get to manually spin :) Don't worry about the STEP files - the stl files are all you need. A Robo R1+ does have enough build volume to print everything, so you're good there. Thanks and good luck!

Thank you so much for your help! I had one follow-up question on the model. Do you have any parts to complete close the exterior hull of the jet engine? The file I was wondering the most about was the inlet fan casing as it a 65ish - 35 ish ratio. The other parts seem to be 50 50 and can be closed directly. Thanks in advance thank you for your time.

The very last file I uploaded, bottom of the list, contains the unsectioned stl parts with the custom supports.

How can i cut off the supports part in the fan? it seems to be very hard

Very carefully with a hobby knife. Sorry if the supports printed too strongly on your model! It was fine on mine, but results can vary.

Thanks for the answer. Finally i made it with some patience.

Could you post your model? I'd like to see it!

Ofcourse, I'm still working on it, I got some more problems:

-The mixer: I use, infill: 30, Layer: 0.2 and Shell: 0.4 but it result in a lot of bubbles all the top layer
-The fan casing: I'm going on try numer 3 and its imposible to be free form Layer Separation and Splitting, always in one of the sides.

I'm using ABS, and Layer of 0,2 in all parts

PD: sorry about my Inglish

ABS is definitely a challenge for these. I only use PLA to those kinds of issues. Good luck!

Sep 10, 2016 - Modified Sep 10, 2016

Firstly, thank you CATIAV5FTW for sharing your outstanding drawings. These must have taken you weeks, so your effort is greatly appreciated. Next time when kids or adults ask about 3D Printing I will simply show them how it applies to mechanical engineering rather than some boring figurine. The time and filament cost are negligible compared with the educational value of printing this working model.

I have started printing the complete turbine engine on a MakerBot Z18 with a new Smart Extruder+ and MakerBot PLA filament. I have chosen to use the files that have the custom supports added in the hope of minimising "stringy" support added by the slicer, and the resultant post-processing.

All the components have been pre-sliceed to determine the mass of filament needed and the estimated time to print each component. This data was recorded in Excel so that the longest prints could be scheduled overnight to minimise non-printing time and complete the entire print in the shortest time possible.

Without scaling the total material mass estimate is 1228 grams (incl support) and the time to print is projected to be a total of 108 hrs 39 minutes. There will be about 10 minutes between prints when the bed is cleared and the next print is started. I plan to lay out multiple smaller components on the bed together after the largest components have printed. The Z18 is connected to a UPS to minimise the chance of wastage due to power glitches.

Colours: The casing is white. Different colours will be used for the high pressure stage, low pressure stage, bypass fan, shafts and stand.

I chose to print the largest item first, being the fan stator casing and supports (with the added support) in white. I figured that if this worked then the other components were likely to print OK too. This took a little over 14 hours to print overnight with the MakerBot Desktop slicer adding in significant required support. The print has turned out well, and will require about an hour of post-processing with a blade, pliers, Dremel and sandpaper to give it an optimal, exhibition-quality finish.

The second item printed was the mixer because I wanted to see the outcome of a component that did not require support. It is superb.

The third item has just started printing - the nozzle with supports. This is estimated to take a little over 10hrs and requires additional support to be added by the MakerBot Desktop slicer software (unless someone has managed to print this successfully without additional support).

T - 4 days and counting....

Comments deleted.

Can't wait to see it! T-1 day...

Printing of all the parts ("with_support" file versions) have been completed on a MakerBot Z18 and assembly is being completed as time permits.

Printing took two weeks not 4 days because the print settings for optimum quality varied considerably from one component to the next, which resulted in many, many reprints.

When multiple items were arranged on the build plate together some came out OK and others not, due to the geometry differences (thickness, component complexity of a fan blade and shaft, for example). It would have been better to print one item at a time so that when print quality was unacceptable, prints of a single item could have been aborted sooner with lower filament and time wastage. An exception would be printing groups of similar items such as a batch of low pressure fans.

Over the print period MakerBot released new firmware twice and a new MakerBot Desktop app once, and this had an effect on print quality, requiring some experimentation to optimise the print quality again.

In hindsight, I would have liked to have printed the largest model that could possibly have fitted in the Z18 since it is better suited to very large components than small ones.

The main issues I encountered were:

  • The support under the main fan did not snap of neatly. I suggest the CAD files be modified so that there is a small groove at the junction of the fan blades and the extra support, or the support be made thinner.

  • There was considerable stringiness between the main fan blades and on the fan blades, requiring experimentation with different settings for temperature, travel speed, retraction distance and retraction speed. Similarly for the small LP and HP stage turbines.

  • The injectors printed very badly until optimal high resolution settings were found, then printed superbly.

  • Multiple colours were used, but the colours with the best appearance were light matt colours. Gloss colours, particularly black, shows up imperfections more than lighter colours.

There were other issues too, and I'll possibly reprint some of the items now that the firmware and software updates have stabilised after the release of the new 6th gen MakerBot printers.

I'll upload photos when assembly is done

Thanks, I apparently downloaded my set of files before you uploaded that set.

Sep 8, 2016 - Modified Sep 8, 2016

I am curious as weather you have files for the removed sections of parts you have removed sections from ?

Not those specifically. I did upload full, 360 deg, unsectioned versions of all the sectioned parts.

Sep 6, 2016 - Modified Sep 6, 2016

Hi CATIAV5FTW,
Are the assembly instructions uploaded? I can't seem to find them. Also, when the part is printed, is there any way to spin (at varying speeds) the outer shaft (as what would be rotated in the presence of combustion) without changing the current design? I noticed the fuel injector feature, will I be able to attach an air compressor and spin the blades this way?
Thanks :)

Depends on the method you use to spin the HP shaft, I suppose. Both shafts spin independently, so pushing air past the HP turbine through the fuel injectors could work. I started on some assembly instructions but I quit because it was a lot of work, and people were already making their own models successfully.

Question: Most parts seem like they'll fit via friction but I can't figure out LPT Stage 1 on the LPT Spool. The angle of both the spool and stage seems like there's no way they'll friction fit together. Is there a trick to it or is an adhesive required?

Yes, the LPT stages (and the spinner stripe) were the only parts that need to be glued.

Answered the exact question I came here for, glue on the LPT. Also, for the record, I was able to assemble with #4-40 x .38 screws/lock nuts using the provided unmodified files.

Sep 8, 2016 - Modified Sep 8, 2016
CATIAV5FTW - in reply to Fierofiend

Nice. I kept plenty of clearance for the holes to account for loose printing tolerances, and unintentionally for flexibility in hardware choices. :) Will we be seeing pics soon?

My printer (Da VInci 1.0A Modded) printed most everything with slightly tighter tolerances. That has given me the ability to tweak the size and press fit everything including LPT stages 2-4. I think stage 1 and the spool could benefit from a small hidden flat step.

Curious if hot glue would work, I don't want to permanently stick anything together.

Have you tried the hot glue? I've never used it on printed parts before fearing that the heat would warp the plastic too much. Let me know how it went if you did.

Hot glue worked perfect for me. No damage to the parts and easily reversible which I did many times. It just peels off leaving no residue or damage.

Interesting stuff, was that PLA or ABS or something else?

ABS, PLA could be a different story.

Comments deleted.

Did you print some of the tall parts, like the Fan casing, standing up or laying down, With supports added or not?

Those were printed vertically, so that the engine spin axis was parallel to the printer z axis. I used supports, yes.

Great project! It's perfect! Could you upload Fan Cut in Half with Supports? I can only find without supports.

Uploaded "Fan - Cut in Half (With Supports).stl"

you say that the parts were designed with a particular orientation in mind, and that there are pictures to go along with this. But from what I can find, all pictures of the models themselves show the parts orientated vertically, which doesn't make too much sense to me. am I missing something here?

If you're referring to the pictures in the zip file, yes, all the parts are to be printed vertically with a specific side facing the build plate.

Sep 19, 2016 - Modified Sep 19, 2016
IsmaelPR1 - in reply to CATIAV5FTW

Can some or most of the parts be printed with a flat side towards the bed and with supports? Or do they need to be printed vertically? I too am wondering about the vertical printing. Thanks for the the design!

Printing vertically would mean printing with the main axis of the engine pointing up along the printer z axis. So, yes, all the parts have a flat side down on the build plate. The orientations in the blue stl file previews don't mean anything. I simply modeled the engine along the horizontal x axis instead of the z axis, so that's why they appear the way they do.

This looks amazing!

wow thanks for sharing! love it!!

This looks amazing! Whats the biggest dimension? My print area is 7.8^3, think it will be a go?

Everything except the stand, yes.

Beautiful, thank you!

Aug 7, 2016 - Modified Aug 7, 2016

Great job, it looks amazing. Is there anyway you can cut the fan casing, the fan stator casing, and the stand in half? Its slightly too big for my printer and I would love to finish printing this.

Uploaded those parts cut in half with supports. I made the cut at 2 different planes on the casings so that they'll hold each other together when you put in all the fasteners. These parts have the existing part name but with the suffix "Cut in Half - Part 1" or "...Part 2".

Great project! It's perfect! Could you upload Fan Cut in Half with Supports? I can only find without supports.

Yes. Do you need the parts with the supports I added or without?

With the supports would be great. Thank you so much for all your hard work

We can only print it at 50% scale, would it work? :/

Unfortunately no, I designed it specifically for this scale. If you really want, you can go ahead and print it, but I don't know if there are any ball bearings and screws that would fit a half-scale version.

I am just getting started on this project. I was wondering if the finished engine is a true 2 spool engine (ie when you spin the fan the core will not spin)?

Yes, the 2 spools spin separately! It is a true 2 spool engine!

hey Catiav5ftw

this is amazing I was wondering if a 2000-3000 RPM motor can be added to this?

my plan is to have it running and a projector simulates the flow and temp of air traveling inside. would be nice to teach concept better this way.

Probably could add a higher RPM motor depending on the type of filament you use.

Yeah, you're right, but be careful with all those turbine propellers, I don't know which filament you're using,of course it could work with basic PHA filament, but just for safety reasons I recommend using something like ColorFabb XT CF20 (Filament enforced with carbon fibers)

I wanted to thank you for this beautiful object.
since yesterday I'm on I select files by color and I set them for my printer. As I am French I have to find the ball and viseries ....

What would be great is to have the cover to the turbine is complete

thanks again

I post pictures soon

is it possible to get a cut from the Fan? 50/50?

What do you mean?

can you cut the Fan without support in the center?

Done.

Thanks!

Is it possible you can upload extra parts without the cutaway? Me and my local makerspace are looking for things to cast in Aluminium.

dude this is wicked bet this fires up when i investment cast all the parts few tweeks to seal the case & stators etc but fans look cool this will blow the fence down I'm sure must post the proff this guys hard work will work for real as an actual jet I'm sure it will im having a go jet pack on the way

May 19, 2016 - Modified May 19, 2016

Every part is now uploaded! I have to create some assembly instructions which will be coming soon...

Really great design! Did you thought about to build a motorized version with two small brushless outrunner motors inside? That would be pretty cool to simulate a spin-on of the engine with the two spools, and some lightnings for the burning chamber, what do you think?

Read my mind was working on such a project myself and chance you have the original design files you could share with us as i would like to make some tweaks to some of the parts to make this a working engine

Do you have Catia V5 R20 or above? If not, I could also upload the STEP files to mess around with. I'd love to see what you have in mind...

So sweet! I've already started on some of the larger parts, and ordered bearings.

I'd love to play with the files too. I only have Solidworks, Catia is WAY more $$$ than my company could justify, but they are both from Dassault Systemes... any chance of getting SW compatible output files (assembly.asm/.sldasm and parts.prt/sldprt)?

Not even sure if Catia supports that... if not ACIS or STEP files would be good too.

So cool, thanks for sharing!

Catia can't export Solidworks files, but I did upload zip files of the STEP files, with and without the extra supports!

Sweet, thanks!

Comments deleted.
May 15, 2016 - Modified May 15, 2016

Hi! Does it rotate freely? It looks awesome. How big is it? And how big is the biggest individual part? If you upload it to My Mini Factory people can give you tips for your designs ;) Thank you so much!

May 15, 2016 - Modified May 15, 2016
CATIAV5FTW - in reply to jjuasjjuas2

Thanks, yes, it does rotate freely with the use of 4 ball bearings. It is about 16 inches long. Biggest part is about 7.5 inches wide. I'll check out myminifactory!

This looks awesome.. let the printing begin!

Mar 18, 2016 - Modified Mar 18, 2016

This is a super cool design! I use to overhaul Jet engines and it was very satisfying. I kind of miss it.

I am currently assembling a printer with a footprint of 18" x 48" inch . This design would be a great build....

Ready to print when you are!!

Uploaded a couple parts. I successfully printed both and am currently printing more. It's so close!

Apr 20, 2016 - Modified Apr 20, 2016
Craz3Coyote - in reply to CATIAV5FTW

Does the shroud go with the stationary vanes you just uploaded? How easy would it be to scale it up a bit?

By shroud, are you referring to the mixer?

The outer housing. The second part in the list.

Yes, those two go together. I've uploaded a picture with the printed parts attached with nuts and screws. Though I could've made them a single piece, I wanted to add some mechanical bling!

It got serious mechanical bling! You did an awesome job on it! Serious wow factor!
I can't wait to have a completed model on my desk. I just finishing up a delta printer made by flightfixit here on thingeverse. Mine has about 900mm print hight. This Turbofan is going to be my next project.

Any more parts to this?

Not yet. Everything is currently 90% done, just needs final tweaks. As they say, the last 10% takes 90% of the time...

Ha! I love that saying.... Must try to use it more in progress meetings at work!...
Awesome design... keep up the good work!

Super cool! I can't wait to see the rest!