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Aerodynamic Testing of a 3D-Printed Aircraft Model with a Post-Processed Surface
Lucjan Setlak1, Rafał Kowalik1, Tomasz Lusiak2
1Department of Avionics and Control Systems, Polish Air Force University, 08-521 Deblin, Poland.
Materials (Basel, Switzerland)
|September 13, 2025
Summary
Surface post-processing of 3D-printed M-346 Master aircraft models significantly impacts aerodynamic measurements. Proper treatment ensures accurate wind tunnel test results for enhanced aircraft design.
Area of Science:
- Aerospace Engineering
- Materials Science
- Computational Fluid Dynamics
Background:
- 3D printing (FDM) enables rapid prototyping of aircraft models.
- Surface finish can influence aerodynamic characteristics.
- Accurate aerodynamic data is crucial for aircraft design and performance evaluation.
Purpose of the Study:
- To investigate the effect of surface post-processing on the aerodynamic characteristics of a 3D-printed M-346 Master aircraft model.
- To validate the hypothesis that surface treatment accuracy affects aerodynamic measurement fidelity.
- To analyze wind tunnel test results concerning forces, moments, and flight scenarios.
Main Methods:
- Experimental wind tunnel testing of a 3D-printed M-346 Master model.
- Utilizing fused deposition modeling (FDM) for model fabrication.
- Measuring aerodynamic forces and moments at various angles of attack and a constant sideslip angle.
Main Results:
- Technological parameters of 3D printing and surface treatment significantly influence the accuracy of aerodynamic characteristics.
- Surface post-processing demonstrably affects the representation of real aerodynamic performance.
- Analysis confirmed the impact on force/moment distribution and structural behavior in simulated flight.
Conclusions:
- Proper surface treatment is essential for achieving accurate aerodynamic measurements in wind tunnel tests of 3D-printed models.
- The study highlights the importance of considering post-processing techniques in aerodynamic research.
- Findings provide practical insights for optimizing 3D printing applications in aerospace engineering.
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