Project Tortas: Flattened Duct for Engine Build-Up

During my involvement in the initial phase (first quarter) of the "Project Tortas: Flattened Duct for Engine Build-Up" senior design project, I played a important role in the foundational design, material research, and fabrication strategy for the flattened duct. My efforts were concentrated on translating the sponsor's (Collins Aerospace) objective of creating a more compact duct system into tangible design iterations and exploring viable prototyping methods.

A primary area of my responsibility was the CAD design and iterative modification of the duct's geometry. Starting with the baseline circular duct STEP file provided by the sponsor, I was involved in transforming the cross-sectional profile to achieve the desired flattening, primarily exploring oval and rectangular shapes. This iterative CAD work, using software like SOLIDWORKS, was crucial for developing duct profiles that fit within the specified design envelope  while aiming to minimize adverse effects on airflow and pressure drop. My contributions to these CAD iterations were instrumental in the early stages of defining the geometric parameters for subsequent CFD analysis and physical prototyping, as acknowledged by the team.   

In parallel with the design work, I took on a significant role in material research and the initial fabrication approach for the duct prototypes. Given that the final duct was intended for metal additive manufacturing, my focus was on identifying and testing suitable 3D printing materials for creating accurate physical prototypes for experimental validation. This involved researching various plastic 3D printing options, including testing with different methods like Fused Deposition Modeling (FDM) and resin printing (SLA) to assess their suitability in terms of surface finish, dimensional accuracy, and ability to withstand test conditions. I investigated materials like PLA  and various resins, considering factors like their temperature resistance, cost, and ease of manufacturing for complex geometries like our duct. This exploration was vital for making informed decisions about how to produce initial test articles effectively.   

Through this first quarter of the project, my hands-on work with CAD modeling and 3D printing material testing provided critical groundwork for the team. I learned about the practical challenges of translating complex CAD designs into physical objects, the trade-offs involved in selecting 3D printing materials and methods for specific engineering applications, and the importance of iterative design in achieving functional prototypes. This experience also highlighted the complexities of designing for fluid dynamics, where subtle changes in geometry can significantly impact performance, and the necessity of balancing ideal design characteristics with manufacturability.