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Blisked Fan design for small drone?

Yes, it is possible to create a 3D-printed blisked fan for a small drone, especially with advancements in additive manufacturing. However, the feasibility, performance, and practicality depend on several factors:


Feasibility of 3D Printing a Blisked Fan

  1. Materials:
    • For prototyping, materials like PLA, ABS, or PETG could be used, but they lack the strength and durability needed for high-performance applications.
    • For functional designs, using nylon blends, carbon-fiber-reinforced polymers, or metal 3D printing (e.g., titanium or aluminum) offers better strength-to-weight ratios.
  2. Printing Technology:
    • FDM/FFF: Useful for prototypes but may not achieve the precision needed for aerodynamic efficiency.
    • SLA/DLP: Provides higher resolution for small, intricate designs but has limitations in material strength.
    • SLS/DMLS: Ideal for functional parts, offering excellent material properties and surface finish.
  3. Design Complexity:
    • A blisk’s integrated design is well-suited to 3D printing, eliminating assembly concerns and allowing for advanced geometries.
    • Tools like CFD (Computational Fluid Dynamics) and FEA (Finite Element Analysis) can optimize blade shapes for aerodynamics and structural integrity.

Potential Performance Gains

  1. Efficiency:
    • The seamless, integrated structure reduces drag and turbulence, leading to better airflow efficiency.
    • Optimized blade profiles can improve thrust-to-weight ratios, extending flight times or carrying heavier payloads.
  2. Noise Reduction:
    • Blisk designs reduce gaps and vibrational interactions, which can lower aerodynamic noise levels.
    • Tailored blade geometries can further minimize tonal and broadband noise.
  3. Weight Reduction:
    • 3D printing allows for lightweight designs with internal lattice structures, potentially reducing the fan’s mass.

Challenges

  • Durability: Plastic 3D-printed parts may suffer from wear or deformation under prolonged operation, particularly at high speeds or in harsh environments.
  • Precision: Achieving the tight tolerances required for small fans can be challenging without high-resolution printers.
  • Repairability: Damage to any blade would require replacing or reprinting the entire blisk.

Estimated Value of the Design

  1. Prototype Cost:
    • A basic FDM-printed prototype could cost $10–$50.
    • A high-performance metal 3D-printed blisk may range from $200–$500, depending on material and complexity.
  2. Market Value:
    • Small, high-efficiency, low-noise fans for drones could appeal to commercial and recreational drone manufacturers.
    • A well-designed blisk could justify premium pricing (e.g., $100–$300/unit) due to performance and durability benefits.

Summary

Creating a 3D-printed blisked fan for a small drone is feasible and could yield significant performance and noise reduction benefits. However, material and printing technology choices are critical to ensuring functionality and durability. If you’d like, I can help design or simulate the performance of such a fan.

Advantages of Connecting the Blades to an Outer Rim:

  1. Structural Stability:
    • The outer rim prevents excessive flexing of the blades, especially under high stress or high-speed rotation.
  2. Reduced Noise:
    • By stabilizing the blades, the outer rim minimizes vibration-induced noise and harmonics.
  3. Enhanced Durability:
    • The rim protects the edges of the blades from damage caused by debris or impacts during operation.
  4. Aerodynamic Benefits:
    • The continuous rim can reduce turbulence and improve airflow by maintaining consistent spacing and alignment of the blades.

Design Options for a Rim-Connected Blisk:

  • The rim could have spokes radiating to the hub for additional weight reduction.
  • Perforations or cutouts in the rim can help reduce weight while retaining strength.
  • The rim could be designed with a beveled edge to further optimize airflow.

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