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Related Experiment Video

Updated: Sep 6, 2025

Methods for Measuring the Orientation and Rotation Rate of 3D-printed Particles in Turbulence
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Performance evaluation of a 3D-printed sharp-cut cyclone.

E Albanes1, S Bezantakos1, M Costi1

  • 1Climate & Atmosphere Research Centre, The Cyprus Institute, Cyprus. g.biskos@cyi.ac.cy.

Environmental Science. Processes & Impacts
|June 29, 2022
PubMed
Summary

3D-printed cyclones offer a low-cost alternative for aerosol metrology. While slightly less efficient than metal versions due to surface roughness, their ease of manufacturing makes them highly promising for particle size analysis.

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Area of Science:

  • Engineering
  • Environmental Science
  • Materials Science

Background:

  • Cyclone separators are crucial for aerosol particle size analysis.
  • Traditional metallic cyclones can be expensive and time-consuming to manufacture.
  • 3D printing offers potential for rapid, low-cost fabrication of scientific instruments.

Purpose of the Study:

  • To compare the performance of a 3D-printed cyclone with a metallic counterpart.
  • To evaluate the suitability of 3D-printed cyclones for aerosol metrology applications.
  • To identify factors influencing the performance differences between 3D-printed and metallic cyclones.

Main Methods:

  • A 1 μm cut-off diameter cyclone was fabricated using 3D printing and compared to an aluminum version.
  • Penetration efficiency was experimentally determined using quasi-monodisperse aerosols (100 nm to 2 μm).

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  • Aerodynamic cut-off diameter and pressure drop were measured for both cyclones.

    • Main Results:

    • Both 3D-printed and metallic cyclones exhibited similar aerodynamic cut-off diameters.
    • The 3D-printed cyclone showed a less steep penetration efficiency curve than the metallic one.
    • Higher surface roughness in the 3D-printed cyclone likely caused its reduced performance and increased pressure drop.

    Conclusions:

    • 3D-printed cyclones are a cost-effective and rapidly manufacturable alternative for aerosol metrology.
    • Surface roughness, not dimensional accuracy, is the primary factor affecting the performance of 3D-printed cyclones.
    • These findings highlight the potential of additive manufacturing for developing specialized aerosol sampling equipment.