3D-Printed Integral Impeller Structure for High-Speed Strength
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing jet engine designs face challenges in improving efficiency and reducing parts count while maintaining mechanical integrity under high stress and rotational speed conditions.
Innovation Solution
A 3D-printed integral impeller apparatus with a central structural member, hub, strength members, core and bypass blades, and a shroud is developed, integrating multiple components into a single unit to enhance mechanical strength and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple components are integrated into a single impeller unit, then mechanical strength and efficiency improve, but manufacturing complexity increases
Solution Approach 1:
The patent integrates the hub, strength members, core blades, and bypass blades into a single monolithic impeller component manufactured via 3D printing. This merging eliminates the need for separate parts and assembly operations, while the additive manufacturing process enables complex internal structures that enhance mechanical strength throughout the integrated component.
2Ease of manufacture
If traditional multi-part impeller design is used, then manufacturing is simpler, but mechanical integrity under high stress deteriorates
Solution Approach 1:
The patent employs 3D printing technology to create an impeller with optimized internal parameters including variable thickness walls, reinforced rib structures, and strategically placed support features that cannot be achieved with traditional manufacturing. These parameter changes enable the single-component design to withstand high stress and rotational speeds while maintaining manufacturing feasibility through additive processes.
3Reliability
If stress concentrations are reduced through integrated design, then reliability improves, but manufacturing precision requirements increase
Solution Approach 1:
The 3D printed impeller incorporates locally optimized features including variable wall thickness, strategically placed reinforcing ribs, and smooth transition zones at critical stress points. These local quality enhancements distribute stress more evenly throughout the component while the additive manufacturing process achieves the required geometric precision through layer-by-layer construction and post-processing operations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The integrated impeller design improves mechanical strength and efficiency, enabling high-speed operation and reducing stress concentrations, suitable for military applications.
Implementation Method 1
a first set of rotating blades may be fan blades designed to push a large volume of air into two distinct regions
Data Source
AI summary
An apparatus includes a central structural member, a hub, and a plurality of strength members coupled to the central member and hub. The hub has a first diameter adjacent to an inflow end of the apparatus and a second diameter, larger than the first diameter, adjacent to an outflow end of the apparatus. A plurality of core blades are coupled to the hub on a side opposite to the plurality of strength members. Tips of the strength members are aligned with roots of the core blades. A shroud is configured radially outboard of the central structural member, the hub, the plurality of strength members, and the plurality of core blades. Tips of the core blades are coupled to the shroud. A plurality of bypass blades are coupled to the shroud on a side opposite to the plurality of core blades. All components are integrally formed and rotate as one unit.