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Nowadays, several procedures are used for manufacturing wind tunnel models. These methods include machining, casting, molding and rapid prototyping. Raw materials such as metals, ceramics, composites and plastics are used in making these models. Dimension accuracy, surface roughness and material strength are significant parameters which are effective in wind tunnel manufacturing and testing. Wind tunnel testing may need several models. Traditional methods for constructing these models are both costly and time consuming. In this research, a study has been undertaken to determine the suitability of models constructed using rapid manufacturing (RM) methods for use in wind tunnel testing. The aim of this research is to improve the surface roughness, dimensional accuracy and material strength of rapid manufacturing models for testing in wind tunnels. Consequently, the aerodynamic characteristics of three models were investigated and compared. The first model is made of steel, the second model from FDM-M30, and the third model is a hybrid model. Results show that metal models can be replaced by hybrid models in order to measure aerodynamic characteristics, reduce model fabrication time, save fabrication cost and also to verify the accuracy of aerodynamic data obtained in aerospace industry.

Investigation of rapid manufacturing technology with ABS material for wind tunnel models fabrication