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Apr 12, 2015, 12:33 AM
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Harcoreta's Avatar
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Build Log

GE GEnx-1B 100mm 3D Printed EDF

Update 06-07-2015


GE GEnx-1B 3D Printed B787 Jet Engine with Thrust Reverser (3 min 51 sec)

Photos on post N#41


Hi to all!
Last year, I built a 3D printed EDF prototype, It works! but only flew in the maiden flight, only had some overheat issues remember....

I decided to build a improved new design, a scale Boeing 787 turbofan. I like too much this aircraft, but for now too much work for build a whole plane xD. When it be done, It'll be tested on bixler plane mounted on top side.
I've almost finished this long time design and finishing to print all parts too, lots of them

Some specs...

100mm diameter 18 blade main fan scale looking. 24 outlet guide vanes.

34 mm diamenter 18 blade internal turbine, installed on the back shaft of the motor, It's designed only for cooling the motor. Over this section there are a sequence of stator vanes and supports to optimize the airflow. This internal airflow could produce thrust but in any case it'll be a few grams xD.

Scale looking nacelle, the major differences are the simplified engine pylon and the minor reduction on the exhaust area, about 95% fsa

Thrust reverser, complete system with translating cowl, blocker doors and cascades. The most complicated parts that must works (fingers crossed xD)

NTM 1400kv 35mm motor. Thrust target > 0.5Kg with 3S or 4S maximum.

I've attached some renders for the desired goal, the internal airflow section detail, and finally the first sections to be assembled

For now and in the future posts, sorry for my poor English.
I'll be updating soon...
Last edited by Harcoreta; Jun 08, 2015 at 03:42 PM.
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Apr 12, 2015, 12:57 AM
Insta: Check5_Av8r
AceMigKiller's Avatar
Looks cool!
Apr 12, 2015, 06:50 AM
Registered User
Larry Dudeck's Avatar
Great rendering, good luck, keep posting
Apr 12, 2015, 09:17 AM
Watt me worry?
Madmax1965's Avatar
Harcoreta :
For now and in the future posts, sorry for my poor English.
You are a talent so don't worry about your English...........I speak "Southern" and it is a good thing I don't write that way(an inside joke).

I am wondering how the blades on the fan will hold out under high speeds.

I am subscribed.
Apr 12, 2015, 04:07 PM
Foam addict
4stripes's Avatar
You should get in touch with Ming
from Windrider

With beautiful fans like that he might produce some new generation large models!
787, 777, 747
Apr 12, 2015, 08:32 PM
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Harcoreta's Avatar
Thread OP
Thanks guys!

Madmax1965, for the start I'm going conservative. I'm looking for low thrust, only 0.5Kg, It's very low for a 100mm diameter fan. I suppose enough for flight a 1.5Kg plane + motor combo. Printed parts are not stronger than a manufactured one. Possibly when the experiment is completed I'll do a destructive testing on a simplified second unit for go to the limits
Other option is manufacture the fan with other materials/technique, nylon, SLA resin 3d printer...

The fan is printed but not finally assembled, I attached some photos... printing process, post finish with a acrylic thinner bath for improve strength and a shiny finish, and a provisional assembly. Edge painting needed also.

4stripes, I like very much his 737 windrider model, might be interesting trying to powering this model

Ups! first problem with the motor mount section, reprinting part. I've attached too the first assembly goal
Last edited by Harcoreta; Apr 14, 2015 at 09:31 AM.
Apr 13, 2015, 04:36 AM
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Eddie P's Avatar
Amazing work!
Apr 13, 2015, 11:43 AM
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Castel101's Avatar
Really cool! Subscribed.

I didn't know you could apply something to the printed parts to improve their texture and make it smooth, care to share details on this? Seems like an easy way to get a nice looking part quickly.
Apr 13, 2015, 07:05 PM
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Harcoreta's Avatar
Thread OP
Castel101. Yes, you can apply acrylic thinner or acetone, only for ABS plastic. I prefer acrylic thinner, I'm getting better results. I bought one liter bottle in a paint shop (+-5$).
For blade finish, I'm putting the the entire blade inside a bottle filled of thinner for 1 min and then left to air dry. 24 hours later can operate with it, time to total cure two days.

For smooth large parts you can apply the liquid with a brush directly to the surfaces.

I'm going to use the thinner too for bonding all parts. You can apply a fine layer of thinner with a brush to all contact surfaces in two pieces. Repeat the operation three times, after, you can bond the two parts. Bonding time over 15 minutes, total fixation over one hour.

New printed part is ok! motor installed and first guide vanes. Turbine photo added.
Apr 14, 2015, 12:14 PM
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Castel101's Avatar
Looks awesome! Thanks for the details!
Apr 16, 2015, 09:29 PM
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Harcoreta's Avatar
Thread OP
Motor assembly Finished!

Detailed photos of sections and turbine installed. Next step outlet guide vanes assembly and Translating cowls.
Apr 16, 2015, 09:37 PM
Foam addict
4stripes's Avatar
Looking very good, but I have one suggestion...
Mounting the motor at the aft end creates a very long moment to where the fan is mounted. Any imbalance will create strong forces on the motor mount. I prefer having the mounting area between the motor and fan to have support closer to the center of spinning mass.
Your design limits the motor length as well.
Apr 16, 2015, 11:04 PM
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Harcoreta's Avatar
Thread OP
you're right! also, any fast acceleration or crash will be dangerous. It isn't the ideal position, very difficult to make an internally similar design to the original.
Apr 17, 2015, 08:47 AM
Registered User
park aviator's Avatar
That is amazing mate your fan would look terific on a scale 747 or maybe a viking
Apr 17, 2015, 07:52 PM
Dont forget the velcro straps
corsair nut's Avatar
holy crap....that's awesome!!!!!!

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