Programming
Design and Fabrication of a Miniature Wind Turbine
A group of mechanical and energy engineering students designed and built a functional miniature wind turbine using the 3D printers and laser cutters in the FabLab. The goal was to create an affordable, open-source prototype to visualize airflow dynamics, study blade geometry, and analyze energy output under different wind conditions.
Difficulty level :
Difficult
Working time :
1 day
Estimated cost :
$300.00
Supplies
- 3D Printer: Prusa i3 MK3S+
- Laser Cutter: Trotec Speedy 300
- Software: Fusion 360, PrusaSlicer, Autodesk CFD
- Material: PLA filament and acrylic sheet
Step 1 : Research and Initial Design
- Students began with a literature review on horizontal-axis wind turbine (HAWT) designs and performance parameters.
- They defined key design constraints: rotor diameter (200 mm), wind speed range (3–10 m/s), and maximum print time (6 hours per part).
- Using Fusion 360, they sketched and modeled several airfoil blade profiles (NACA 2412, 4415, and 6409).
- Each design integrated a hub connector compatible with a small DC motor acting as a generator.
Step 2 : Simulation and Optimization
- The models were tested using Computational Fluid Dynamics (CFD) tools integrated into Fusion 360.
- Students simulated airflow over the blades to analyze lift, drag, and torque output.
- Parameters such as blade pitch, twist distribution, and chord length were optimized iteratively.
- The final model achieved a 22% higher efficiency compared to the baseline blade design.
Step 3 : Fabrication and 3D Printing
- Each blade was printed in under 2 hours on a .
- The hub and stand were laser-cut from 5 mm acrylic for stability.
Step 4 : Assembly
- The blades were attached to the hub using press-fit connectors and balanced with small weights for rotational stability.
- The hub was mounted on a 3D-printed bearing housing connected to a mini DC motor acting as a generator.
- Wiring was soldered to LEDs and a multimeter to measure generated voltage during tests.
Step 5 : Experimental Testing
- Testing was performed using a variable-speed wind tunnel built in the lab.
- Each blade configuration was tested at 3, 5, 7, and 10 m/s wind speeds.
- Output data (voltage and RPM) were collected and analyzed.
- The best configuration (3-blade, 12° pitch) produced 2.4 V at 10 m/s wind speed.
