Alberto Sanchez Ramirez

Purpose: The purpose of this paper is to analyze the aerodynamic improvements obtained in a wing section with a NACA 0018 airfoil manufactured using the fused deposition modeling (FDM) technique with regard to a smooth surface made by milling. The creation of micro-riblets on the surface of the airfoil, due to the deposition of the material layer by layer, improves the general aerodynamic performance of the parts, provided that the riblets are parallel to the flow line. The incidence of the thickness of the thread deposited in each layer – to be the variable on which the geometry of the riblets is based – was studied. Design/methodology/approach: The wing section was designed using 3D software. Three different models were designed by rapid prototyping, using additive and subtractive manufacturing. Two of the profiles were manufactured using FDM varying the thickness of the layer to be able to compare the aerodynamic improvements. The third model was manufactured using a subtractive rapid prototyping machine generating a smooth surface profile. These three models were tested inside the wind tunnel to be able to quantify the aerodynamic efficiency according to the geometry and the riblets size. Findings: The manufacture of an aerodynamic profile using FDM provides, in addition to the lightness and the ability to design parts with complex geometries, an improvement in the aerodynamic efficiency of 10 per cent compared with profiles with a smooth surface. Practical implications: With the aerodynamic advantage gained through the use of FDM positions, the additive manufacturing serves as an excellent alternative for the manufacture of lightweight aerodynamic parts, with low structural loading and with low Reynolds number (∼5·105). This technological advantage would be applied to the UAV (unmanned aerial vehicle) industry. Originality/value: The study carried out in this article demonstrates that the use of FDM as a manufacture process of end-used parts that are subject to movement generates an additional advantage that had not been considered. The additive manufacturing allows us to directly manufacture riblets by creating the necessary surface so as to reduce the aerodynamic drag.

The purpose for this study is to obtain a new composite manufacturing system based on Additive Manufacturing techniques that allows the creation of parts for the medical industry. These pieces will be resistant, lightweight and may have geometries more complex than those created with traditional systems of composite material. The new system is based on the union of two heads on a 3D Rep-Rap printer. One of the heads is an extruder head of thermoplastic Fused Filament Fabrication (FFF) and the other is a dosing head, based on the Robocasting technique, designed to be assembled on the 3D printer. Thermoplastics material and epoxy resin will be used. The alternate printing of both materials generates a piece of composite material. This new technique will allow to increase the structural properties of the piece in the XY plane. The new additive manufacturing system allows to obtain mechanical improvements both in the modulus of elasticity and in the tensile strength. Increase the modulus of elasticity of a value between 50 and 80% depending on the thermoplastic filament used. In the same way the tensile strength has increased between 50 and 60%. The improvement in the strength / weight ratio allows to this new additive manufacturing system to create medical pieces in which the lightness and resistance are its main characteristic, such as orthopedic prostheses.The results show that the use of FFF together with Robocasting, as a manufacturing process for end-use parts, generates an additional advantage that had not been considered until now. The combination of a thermoplastic and an epoxy resin opens a new path in the additive manufacturing since it allows creating pieces with new qualities without being conditioned by the design.