UPDATE (19/04/2019) - VERY IMPORTANT
1, As a few people have raised issues with removing custom supports from a number of parts (especially the Turbine blades) without damaging the parts, I've uploaded the STLs of these parts without custom supports. You can use your slicer software to create your own supports for them.
Please download folder "14_Part without custom supports.zip".
2, I'm overwhelmed by the number of people whom have contacted me in the last few months to share their stories about how they have used my Jet Engine Model for STEM outreach. So, I've decided to share the EXTREME Version pack today to help you convert your jet engine model from a STANDARD Version into this EXTREME Version. All you have to do is download folder "15_EXTREME Version pack.zip", print these additional files and add them onto the STANDARD model.
3, In order to help you handle your EXTREME Version model safely, I've created a few more slides with some Dos and Don'ts. Please download the "DOs and DONTs.pdf"
Finally, I'm currently working on a STEM Project for Rolls-Royce called 'Giveaway Jet Engine Model'. The goal of this project is to raise STEM awareness by making a super special 3D printed Jet Engine Model and give it away for FREE at the end of the project to support people whom are passionate about STEM. If you are interested in supporting this project by helping me spread the words or want to know more, please find project milestones via the links below:
15/02/19 - Video #1: https://bit.ly/2Dd6whx
05/03/19 - Update: https://bit.ly/2CZn9x2
10/03/19 - Video #2: https://bit.ly/2I4Stye
16/03/19 - Update: https://bit.ly/2G24qBo
30/03/19 - Update: https://bit.ly/2VrwEMs
14/04/19 - Video #3: https://bit.ly/2KQNu6F
A few people have asked me about the White Stripe (the one that fills the swirl inside the Nose Cone) that seems to be missing.
In my original design, I actually painted the White Stripe on the Nose Cone. That why I didn't design this part in the first place. However, since many people have asked, I've decided to design it :). Please download the new folder "13_Nose Cone (Update).zip"
You'll find the White Stripe in the sub-folder "Nose Cone #1". You would print this part flat and then glue it into the groove on the Nose Cone.
If you have a dual-extrusion printer, you can print the White Stripe directly on the Nose Cone - this is what I did on the EXTREME Version (I printed this model on an Ultimaker S5). If you want the file which I designed specifically for dual-extrusion printers, please look into the sub-folder "Nose Cone #2".
As part of my ongoing commitment to promoting STEM via 3D printing, I'll be making a SPECIAL EDITION of the Jet Engine Model – which is an upgraded version of the EXTREME Version model and I will GIVE IT AWAY for ABSOLUTELY FREE as an educational kit to help other people whom are also passionate about STEM and want to inspire the next generation about Engineering
If you would like to receive this SPECIAL EDITION of the Jet Engine Model, please visit my post on LinkedIn for joining instructions. Thank you
1) In order to make the Fan spin much better and minimise assembly error during the build process, I've redesigned the LP Turbine Dics (ID #50) and LP Turbine Drum (ID #51).
In the original design, you'll need to print these two components separately with a lot of supports, and then bolt them together using eight M3 screws.
In the new design, I've combined them so you will be able to print them as a single piece, with minimum support required. This has removed the need to assemble and also increased the accuracy of the design.
I've uploaded the new design in folder "12_New LP Turbine Drum.zip".
2, I've created a few A3 size posters for the model. You can download and print out these posters if you like. Please download the "Poster.pdf" file.
If you are not able to print the whole Fan in one piece due to your printer build volume not being large enough, I've split the Fan in into smaller sections for you. Please download folder 11_Fan (Split).zip.
As many people have contacted me and asked about the additional parts on the EXTREME Version and I can't answer every email one by one (apologies if you have sent me an email/message and haven't heard back from me yet).
Here is what I would do from now on:
I'm willing to share the Optional Package for you to make the EXTREME Version of the model with TWO conditions:
1, You need to complete the STANDARD Version first (so I know that you are serious about making this model). After you send me some photos of your printed model as proof, I'll send you the link to download the Optional Package
2, You will ONLY use the model for educational purposes, not commercial
To contact me, you can either drop me a message via my LinkedIn (https://www.linkedin.com/in/duongan) or my email firstname.lastname@example.org
IF YOU CAN'T FIND THE ADDITIONAL PARTS, PLEASE READ SECTION IV) ADDITIONAL INFORMATION BELOW
6 months ago, I came across a model of a 3D printable 2-shaft jet engine on Thingiverse which was designed by CATIAV5FTW
I was really impressed by his work and then I thought “hey, why don’t I design something similar, perhaps a 3D printable 3-shaft Jet Engine model?”
So, I decided to give myself a project after work: Design one!
This has been the most complex, challenging, time-consuming but also exciting model that I have ever created for 3D printing! I've been sharing the progress of this project on my LinkedIn since day one and it's been such an incredible journey to get this design from concept to reality:
Originally, I designed this jet engine model solely to support my STEM work at the University of Nottingham. I've always wanted to have an educational kit to explain to the students how a 3-shaft jet engine works. However, since the project has unexpectedly generated a lot of interests, I've decided to share my work publicly so anyone who loves 3D printing or have access to a 3D printer can also download my design for free, make a model and use it for educational purposes.
I'm very passionate about 3D printing, STEM and I've always wanted to contribute some of my work to inspire the young people to pursue their careers in Engineering :)
II) ABOUT THIS MODEL
I used two main sources to design:
- I downloaded CATIAV5FTW's jet engine model and used it as a guide to design mine.
- I designed everything from scratch (besides a small number of parts that I borrowed from CATIAV5FTW's model) with visual cues from the Rolls-Royce Trent 1000 app that I downloaded on my iPhone **
The jet engine model has 3 shafts: Low Pressure (LP), Intermediate Pressure (IP) and High Pressure (HP), supported by 6 roller bearings and rotates independently of each other. The other interesting fact is it has the same Modules just like a real engine (e.g. Fan, IP Compressor, HP System, IP Turbine, LP Turbine, etc). Each module is built independently and assembled together at the end in a very similar way to how a real jet engine is built.
Some interesting figures about this model (Standard Version only)
Total print time: 204 hours (exclude the stand)
Fan Case Dia: 310mm
Weight: 4.5 kg
** Although I based my design very loosely on the Rolls-Royce Trent 1000 app, I did not use any sensitive data/information to design any part of this model. My design has been reviewed and approved by relevant personnel to confirm that the model does not contain any IP before I release the design to the public. If you need proof of approval, please drop me an email via my work email address.
III) HOW YOU CAN MAKE THIS MODEL YOURSELF
*** Very Important: Before you print any part of this model, I highly recommend you to calibrate your 3D printer as good as you possibly can. You can simply download the XYZ 20mm Calibration Cube via https://www.thingiverse.com/thing:1278865 and use it for calibration. This is because the jet engine model contains lots of moving parts. If your printer is out of calibration, it may produce parts which are out of spec, and your model won't spin very well at the end.
1, I've organised all the SLT files for each Module in separate folders so you can download and build them separately.
2, For assembly instructions, please follow my instruction via the series - "HOW TO BUILD A JUMBO 3D PRINTED JET ENGINE MODEL" on my LinkedIn (or YouTube).
As this is a complex model to build, I recommend you assemble it the same way as I did. If not, you might not be able to connect the right Modules together (LP, IP & HP)
Originally, I uploaded all the videos on LinkedIn only, however, as many people don't have LinkedIn accounts, I've also re-uploaded them on YouTube. If you want to use the YouTube links below, please just copy the link and delete the bracket after “https”. Sorry for the inconvenience but that’s the only way I know to prevent too many videos from being embedded after the cover photo.
PART 1 - [MODULE BUILD]
[01/10] High Pressure (HP) System
[02/10] Intermediate Pressure (IP) Compressor
[03/10] Intermediate Case & Intermediate Pressure (IP) Turbine
[04/10] Low Pressure (LP) Turbine
[06/10] Fan Case
PART 2 - [ENGINE BUILD]
[07/10] Standard Version (Cutaway Version)
[08/10] Full Version (Unsectioned with detachable Casing and Additional parts)
[09/10] Upgraged Version (Motorised)
[10/10] EXTREME Version
3, You can download the Excel Spread Sheet - "Jet Engine Model (BOM).xlsx" and use it to keep track of your progress.
4, I've included custom supports for a number of parts which contain curved overhanging surfaces as they are much better than the grid-like support that your slicer software can auto-generate. Please refer to column "Custom Support" in the "Jet Engine Model (BOM).xlsx" to find out which part has these built-in support. Please note that you still need to generate normal supports using your slicer software for a number of parts which have flat overhanging surfaces (e.g. Fan Case Mid).
5, The largest part (in terms of footprint) in this model is the Fan Body, which has a fan diameter of 270mm. This is because this model was printed on a CR10 3D printer so I wanted to fully ultilise its build volume (300x300x300mm)
Please note that the EXTREME Version was printed on the Ultimaker S5
6, Below are the list of non-printed parts that I used in this model. They are all standard parts and you can easily get them from anywhere.
- M3 x 12mm Hex Socket Cap Screw
- M3 Hex Nut
- M3 Plain Washer (0.5mm thickness)
- M4 x 16mm Hex Socket Button Screw
- M4 Hex Nut
- M4 Plain Washer (0.8mm thickness)
- Open Ball Bearings (2-off): Inside Dia 20mm, Outside Dia 47mm, Race Width 14mm
- Open Ball Bearings (4-off): Inside Dia 17mm, Outside Dia 35mm, Race Width 10mm
7, For the LP Shaft, I purchased a 9mm Dia Steel rod and machined 2 ends. If you want to do the same, please find the drawing of the LP Shaft - "LP Turbine Shaft_DWG" in folder No.10_Others.zip.
However, if you don't have the equipment to mill the 2 ends of the Steel rod, don't worry, just use a saw blade to cut the rod to the right length (340mm) and print these two parts instead: Fan Shaft (Alternative) and LP Turbine Disc (Alternative). You can find these in folder No.10_Others.zip.
8, You'll need to purchase some magnets to mount the Exhaust Nozzle to the Tail Bearing Housing. The one that I used is: 10mm dia x 2mm Neodymium Magnet.
You can get them from here
9, You'll need super glue to glue the parts together (refer to my instruction videos).
Please note: there are locating features on every Casing. Please ensure that all the Casing fit together nicely before you glue them together!. Otherwise, you won't be able to salvage them later on!.
10, Once you have fully built your model, if any shaft doesn't spin smoothly, this is probably because some blades are rubbing against the Casing (due to various reasons e.g. your printer is out of calibration, assembly errors, etc.). All you have to do is investigate which blades are rubbing and use a file to grind off their tips to increase tip clearance between them and the Casing.
If you want to follow my progress or other 3D printing projects that I'm working on, please find me on LinkedIn
Finally, I hope you''ll enjoy making this model as I did :)
Please let me know if you have any questions.