Comparing the aerodynamic characteristics of wind tunnel models produced by rapid prototyping and conventional methods

Abstract

Initial studies of the aerodynamic characteristics of proposed launch vehicles can be made more accurately if lower cost, high-fidelity aerodynamic models are available for wind tunnel testing early in the design phase. This paper discusses the results of a study undertaken at NASA's Marshall Space Flight Center to determine if four rapid prototyping methods, using a variety of materials, are suitable for the design and manufacturing of highspeed wind tunnel models in direct testing applications. It also gives an analysis of whether these materials and processes are of sufficient strength and fidelity to withstand the testing environment. In addition to test data, costs and turnaround times for the various models are given. Based on the results of this study, it can be concluded that rapid prototyping models show promise in limited direct application for preliminary aerodynamic development studies at subsonic, transonic, and supersonic speeds.