Trystan Casey
Electric ducted fans are mechanical fans mounted inside a cylindrical shroud or duct. They are more effective at generating thrust than traditional propellers and are often used in drones. Building an electric ducted fan requires knowledge of electrical engineering, including an understanding of voltage and battery power. The number of batteries required depends on the desired power output, with higher voltages needing more batteries. The thrust generated by the fan depends on the number and pitch of the blades, the diameter of the propeller, and the power of the motor. 3D printing is often used in the construction of electric ducted fans, with various online resources providing free STL files for download.
| Characteristics | Values |
|---|---|
| Parts | Electric DC motor, plastic propeller, wires, switch, plywood, zip ties, batteries |
| Motor | 3V DC motor, powered by 2 AA batteries |
| Thrust | Depends on the number and pitch of blades, diameter of the propeller, and power of the motor |
| Cost | Depends on the thrust to be generated, a 3D-printed ducted fan producing 323gm of thrust costs around $20 |
| Airspeed | Higher airspeed, smaller in size, produces less noise |
| Design | 3D printed, with a variable nozzle to control the "exhaust" |
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$25.99
Choosing the right motor
When building an electric ducted fan, choosing the right motor is crucial. The performance of your fan depends on several factors, including the number and pitch of the blades, the diameter of the propeller, and the power of the motor. Here are some detailed guidelines and considerations to help you choose the right motor for your electric ducted fan project:
Firstly, understand the basic requirements of your fan. Determine the desired thrust, propeller size, and voltage requirements. Thrust is the force that propels the fan forward, and it depends on the power of the motor and the design of the blades. A larger propeller diameter and higher pitch will require a more powerful motor to achieve the same thrust as a smaller, lower-pitched propeller. Therefore, consider the size and pitch of your propeller when choosing the motor.
Next, consider the power source for your motor. Electric ducted fans are typically powered by batteries, which provide direct current (DC) voltage. The most common type of battery used is the "AA" battery, which supplies 1.5 volts each. To achieve the desired voltage for your motor, you may need to connect multiple batteries in series or parallel. Ensure that the motor's voltage requirements match the voltage supplied by your batteries.
Now, let's discuss motor types. For electric ducted fans, DC motors are commonly used because they are compatible with battery power sources. Within the category of DC motors, you can choose between brushed and brushless motors. Brushed DC motors are typically less expensive and easier to control, but they may require more maintenance due to the presence of brushes. Brushless DC motors tend to be more efficient, durable, and suitable for higher speeds, but they are also more expensive and complex to control.
Additionally, consider the kV rating of the motor. The kV value represents the number of RPM (revolutions per minute) per volt that the motor can achieve. A higher kV rating indicates that the motor is designed for higher speeds and lower torque. Commercial ducted fans typically use very high kV motors, but for your project, a lower kV motor may be more suitable, depending on your specific requirements.
Lastly, don't forget about mounting and clearance. Ensure that you have an appropriate mount for your chosen motor, and verify that it has sufficient clearance to rotate the propeller without any obstructions. Secure the motor firmly in place, as the airflow generated will create a backward force on the motor. You can use various methods, such as gluing, zip ties, or custom-built mounts, to ensure a stable and secure mounting solution.
In summary, choosing the right motor for your electric ducted fan involves considering factors such as thrust requirements, propeller size, voltage compatibility, motor type, kV rating, and mounting options. By carefully evaluating these factors, you can select a motor that meets your specific needs and ensures optimal performance for your electric ducted fan project.
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Designing the fan
The first step in building an electric ducted fan is to gather the required components and materials. The core component is the electric motor, specifically a DC motor, as it is powered by batteries which supply DC voltage. A 3V DC motor is suitable for a basic handheld fan design, powered by 2 AA batteries. For more powerful applications, a higher voltage motor and a greater number of batteries may be required. For example, a 4V or 8V setting can be achieved with 4 AA batteries, with the former being a good low-power setting.
The next component is the propeller, which can be made of plastic. The propeller attaches to the shaft of the motor, and when the motor spins, so does the propeller, creating thrust. The thrust generated by the fan depends on the number and pitch of the blades, the diameter of the propeller, and the power of the motor. The fan can be designed with a single or dual propeller setup, with the latter providing greater thrust.
To mount the motor and propeller, a duct made of plywood can be constructed. The duct can be cylindrical in shape, and the motor can be secured with glue and zip ties. It is important to ensure that the motor has enough clearance to rotate the propeller within the duct. The duct can also be 3D printed, which allows for more complex designs and improved efficiency and thrust through the addition of a variable nozzle at the rear.
Overall, the design of the electric ducted fan involves careful consideration of the components, materials, and their assembly to ensure safe and effective operation.
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3D printing the parts
3D printing is a great way to build an electric ducted fan, and you can find many of the parts you need online. STL files for 3D printing an electric ducted fan can be downloaded from sites like TheMechNinja, which provides all the files you need for free. These files can be used to 3D print the outer casing, diffuser, and nozzle of the ducted fan.
The duct system can be 3D printed, and you can even design and print a variable nozzle to control the "exhaust" of the fan, improving efficiency and thrust. The nozzle can restrict or open up the outflow, mimicking a real jet engine. This is achieved by using two servos connected to collars on the outside of the engine, which then move a set of flaps to choke or expand the opening.
You can also 3D print the shroud, which is the mounting point for the landing legs and servos that control the vanes. These vanes deflect the airstream and provide the thrust vectoring that controls the machine.
In addition to these parts, you can 3D print the duct wall and motor mount arms. For the duct wall, you will need 1/8" plywood, and for the motor mount arms, you will need plywood and 2x1. You can glue these parts together and to the motor, ensuring there is enough clearance for the propeller to rotate.
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Assembly
To build an electric ducted fan, you will need the following components:
- A DC motor (drills can be a good source for this)
- A propeller (plastic or fan blades)
- A power source (batteries or power cells)
- A switch
- Wires
- Plywood for the duct wall and motor mount
- Zip ties
- Electrical tape
The first step is to mount the motor and rotate the propeller to ensure there is enough clearance. You can then cut the plywood to size and glue it to form the duct and motor mount. Ensure the motor is secure and won't slide backwards by using a piece of wood or zip ties.
Next, solder the wires to the motor and wrap them in electrical tape to prevent short circuits. Attach the propeller to the motor shaft. You can then attach the switch to the power source and motor, allowing the fan to be turned on and off.
Finally, test your fan at different voltages to find your desired setting. A higher voltage will increase the thrust of the fan.
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Testing
Another important consideration during testing is the shape of the duct. If the circumference of the duct is not perfectly circular, it can cause a decrease in thrust and possibly lead to fan blade or EDF unit failure. Therefore, it is crucial to perform a smoke or vapor test to ensure that the fan blades do not make contact with the duct and that there are no vibrations.
Additionally, it is important to balance the EDF to eliminate vibrations that can cause problems during flight. Unlike traditional propellers, EDFs do not provide instant thrust, so it is essential to allow for a longer runway during takeoff.
When testing the EDF, it is recommended to have some experience flying 4-channel airplanes. This will help you better understand the performance and handling characteristics of the EDF aircraft.
Overall, thorough testing of an electric ducted fan is crucial to ensure its safety, performance, and efficiency. By constructing prototypes, performing smoke tests, and balancing the EDF, you can optimize the design and thrust capabilities before investing in more expensive factory-made components.
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Frequently asked questions
An electric ducted fan is an air-moving device that consists of a mechanical fan (a form of propeller) mounted inside a cylindrical shroud or duct.
You will need an electric DC motor, fan blades, a power source (such as batteries), wires, and materials for the duct and mounting.
First, mount the motor and fan blades to ensure sufficient clearance and rotation. Secure the motor with glue, zip ties, or other fasteners. Then, connect the power source to the motor using wires, ensuring the voltage and current meet your desired settings. Finally, test and adjust as needed.
The thrust generated by the fan depends on the number and pitch of blades, the diameter of the propeller, and the power of the motor. The design of the duct and nozzle can also impact efficiency and thrust.
