Problem

Our wind turbine project confronted the challenge of translating theoretical concepts into a functional, lightweight model that could deliver measurable power while withstanding practical testing constraints. We needed to design rotor blades, a supporting tower, and a generator housing using SolidWorks, then fabricate and assemble them as a cohesive system. The primary goals were to maximize power generation, minimize drag, and ensure structural stiffness under load, all within a sub-300 gram target for the printed model. This required balancing aerodynamic efficiency with mechanical integrity to prevent deflection or failure during testing.

Early stages demanded extensive research into blade profiles, airfoil shapes, and the interplay of blade count, angle of attack, and angle of twist. We sought a design that would perform reliably across varying wind speeds while remaining lightweight. We also documented a clear path from concept to fabrication and integrated a visual reference that summarized our blade concept decisions.

Solution

We executed a structured design process: brainstorm concepts, select an optimal blade and tower configuration, then model and print the components before assembly. The blade array employed a three-blade configuration with a NACA 6409 airfoil captured in our CAD sketches, aiming to maximize kinetic energy conversion while maintaining low drag. We iterated on blade twist and angle of attack to balance peak performance with stability, and we prioritized a robust motor housing within the tower to secure the generator and wiring. The result was a modular, printable design capable of rapid fabrication and testing.

Following CAD modeling, we produced 3D prints, assembled the turbine, and conducted testing to evaluate power input and tower stiffness. Our turbine achieved a maximum power output of 1.332 W at 2.64 V, with measured tower stiffness around 19.62 N/mm at 0.1 kg and 9.17 N/mm at 1 kg. These metrics validated our design constraints and informed potential improvements for future iterations. This phase underscored the importance of iterative testing in transforming theory into a validated, functional prototype.

Project Report

https://docs.google.com/document/d/1G0HjSaB2P0bNmiFEIYON3uhe7aUgfHALt3ESLqmkSq4/edit?usp=sharing

3D Printed Wind Turbine