Rapid Model Fabrication for Responsive Aerodynamic Experimental Research

Technicians machine traditional metal wind tunnel models in a process that can span months. Although these models are highly precise, the meticulously slow manufacturing process precludes a quick assessment regarding a new design's feasibility and thus impedes the ever-increasing need to help today's warfighter address constantly changing warfare threats. In support of the Integrated Rapid Aerodynamics Assessment program, AFRL has been exploring the impact of rapid prototyping (RP) technology in meeting this escalating need. According to AFRL's Mr. Gary Dale, an originator of this experimental research effort, "We were looking for a way to quickly generate experimental data that we could use to verify computational fluid dynamics (CFD) results. The CFD researchers were generating solutions in a matter of days or even hours, and they wanted to verify their solutions with [wind tunnel] experimental data." By producing a model in days—or possibly hours, depending upon model complexity—RP technology enables this concurrent study of air vehicle concepts via computer simulation and wind tunnel results.