Wind Tunnel V1
The development of a deep understanding of aerodynamic concepts
This project was made possible as a result of the generous support provided by local firms. I would like to thank:
Waveney Precision
Supporting the project by supplying the acrylic for the entire project.
Check them out! →
12th July 2025
The fan bracket assembly is now complete, with labels for fans for easy identification and replacement as well as airtight side walls to ensure all airflow and pressure is directed into the plenum box.
12th July 2025
With the test section assembled, I can now focus on the lighting. The goal is to evenly illuminate the test section while minimizing shadows and reflections. The first, method I tried was to illuminate with two parallel strips. I settled for the LED strips attached to the top corners pointing 45 degrees into the centre.
12th July 2025
With the test section having its major components 3D printed or sourced, assembly can begin. The design has been optimized for ease of assembly using the plastic welding technique and took a short amount of time to put together.
An issue that I noticed was how reflective the back panel of the test section is, which may cause a lack of contrast in any visuals. To solve this, I will test an offcut of acrylic with different surface finishes to determine the best solution to this problem.
12th July
To avoid using super glue, creating a mess and potentially ruining the appearance of parts, I used plastic welding by using a soldering iron to melt the joints between parts. This technique allowed for strong joints with almost unnoticeable seams.
9th July
To get a rough idea of what the final design will look like, I assembled the completed pieces, using the acrylic (with wrap still applied). The design will accommodate large models and allow for great visual testing.
9th July 2025
The fan bracket has been designed, 3D printed and mounted. Initial tests show that it is able to hold the fan securely in place while also allowing for easy removal and replacement. The LED's have also been tested and are very bright and consistant - perfect for illuminating the test section.
6th July 2025
Due to issues with the original buck converter (coil whine and high temperatures), I have replaced it with a new model that has better thermal performance and higher current capacity. The new buck converter is showing no issues and all 9 fans run perfectly.
30th June 2025
With sponsorship of the acrylic for the test section and plenum, I am now able to being working on the parts the acrylic will connect to. The first one I started with was the airflow diffuser, mainly due to 3D printing filament constraints.
27th June 2025
To save on cost for powering the fans, I will be using an old laptop power supply and SATA power cable. To ensure this will be safe and set up correctly, I used an online SATA pinout diagram to work out which terminals are which. This then allowed me to decide on a DC-DC buck converter to take the 19V from the laptop PSU and convert it to the 12V the SATA cable is expecting.
(I am using SATA as the fan hub the design uses is powered by SATA)
12th June 2025
With the CAD complete, I could now being the manufacturing of the parts needed in the build. To start, I 3D printed the most complex part: the airflow straightener.
To test the fit, I used masking tape to hold all the parts together and found it fit excellently.
9th June 2025
After researching wind tunnel design, HVAC concepts such as plenums and setting the project goals, I designed the first version of the wind tunnel using Fusion 360. The design is split into 4 main parts:
- Plenum Box - smooths turbulent air from PC fans
- Airflow Straightener - directs airflow laminarly out of the plenum box
- Test Section - clear front panel allows easy viewing of airflow over models
- Air Diffuser - reduces back pressure by allowing air to flow cleanly out of the test chamber
To read about the entire project, click the link below:
Wind Tunnel V1 →