Improving the fidelity of aerodynamic probes using additive manufacturing

Purpose This paper aims to offer the aerodynamic testing community a new procedure for manufacturing high-quality aerodynamic probes suitable for 3D flow measurements with consistent geometry and calibration by taking advantage of the additive manufacturing technology. Design/methodology/approach The design methodology combines the advantages and flexibilities of computer aided design (CAD)/computer aided manufacturing (CAM) along with the use of computational fluid dynamics to design and analyse suitable probe shapes prior to manufacturing via rapid prototyping. Findings A viable procedure to design and possibly batch manufacture geometrically accurate pneumatic probes with consistent calibration is shown to be possible through this work. Multi-jet modelling prototyping methods with wax-based support materials are found to be a cost-effective method when clean and long sub-millimetre pressure channels are to be cut. Originality/value Utilisation of the geometry consistency that is made possible by 3D printing technology for the design and development of pneumatic probes is described. It is suggested that the technique could lead to batch production of identical probes, thus avoiding precious time of a skilled labourer and elaborate individual calibration requirement.