Wind tunnel testing is a reliable means for aircraft design. The wind tunnel models are the objects used in the tests. The accuracy and economy of the model design and fabrication have an important impact on the quality and cycle of aircraft development. Additive Manufacturing (AM, or Rapid Prototyping, 3D printing) can directly fabricate 3D parts through accumulating raw materials, and is widely regarded as a revolutionary advancement in manufacturing technology.
In the very early development period, AM was soon introduced and was studied by many groups worldwide. Firstly, the introduction of AM is an advancement for the fabrication of models, which can greatly improve the fabrication economy of current models, such as reducing the number of parts, and shortening the processing cycle etc. Secondly, the introduction of AM can also improve the design of models, which is helpful to develop new types of models and even new test methods. Thirdly, AM has blurred the boundaries between real aircraft and experimental models, and promoted the development of new concept aircraft.
The review first introduces the design requirements of the wind tunnel test models and recalls the AM application history for models. Next, detailed technologies concerning the design procedure and fabrication processing of the AM-based models are presented. Finally, the application of AM-based model in the development of current air vehicles and new-concept vehicles is introduced. The review provides an overview of techniques of AM in wind tunnel test models, and provide typical examples for reference to designers and researchers in the aerospace industry.
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