Client Supplied Drawings

The first step of the project involved reviewing the client-supplied drawings of the electric generator and a CAD file of the turbine. Our team analyzed these files to understand the existing design and determine necessary modifications for 3D printing. The turbine model was then reverse-engineered and adjusted to optimize its performance, material compatibility, and manufacturability for prototype testing.

First Design Iteration

In the first design iteration, we began by converting the client-supplied OBJ file into a STEP format, allowing for easier modification and reverse engineering. This conversion enabled us to refine the turbine’s design, optimizing blade geometry and structural integrity for improved performance.

Second Design Iteration

In the second design iteration, we refined the turbine by optimizing the nose cone to improve water flow and overall efficiency. Structural reinforcements were made to enhance durability, ensuring the prototype could withstand testing conditions. Additionally, we incorporated a duct around the turbine to better channel water and increase performance. This finalized design was then 3D printed for prototype testing.

First Prototype Manufactured

The finalized turbine design was 3D printed in ABS, chosen for its durability and suitability for testing. After printing, the individual components were assembled and bonded using epoxy to ensure a secure fit. This completed prototype was then prepared for real-world evaluation.

Design of Second Prototype

During initial testing of the first turbine prototype, we observed that the epoxy-bonded joints lacked sufficient robustness under operational conditions. This led us to redesign the turbine, replacing the epoxy joints with mechanical fasteners, such as screws, to enhance structural integrity and facilitate easier assembly and maintenance. Incorporating mechanical fasteners also allowed for better stress distribution and the ability to disassemble and reassemble components as needed.

Second Prototype Manufactured

In the development of the second turbine prototype, we 3D printed the redesigned components and assembled them using mechanical fasteners to enhance structural integrity. After assembly, we prepared the prototype for overseas shipment by carefully packaging it to prevent damage during transit. This included disassembling removable parts, wrapping individual components in protective materials, and securing them within a sturdy box. Proper labeling and documentation were also provided to facilitate smooth customs clearance and handling.