by terbucn
Rolls Royce Trent 900 is a three spool jet engine that powers largest passenger aircraft in the world, Airbus A380.
I designed this based on the superb CAD model from Chris Shakal. The model is re-designed in a way, that only one part requires support. Most of the parts is printed with 0,15mm layer thickness, but you can chose your own. I chose this layer thickness, as it is very good compromise between speed and details. The walls are also optimised for 0,4mm nozzle (Auto/0,48mm extrusion width in Simplify3d) so there is no too thin walls that would not be printed.
The most important detail of this engine is that it is powered by electric motor and spools are connected with planetary gears. Although because it seemed more interesting to me, the spools do not rotate in realistic order.
I hope you will enjoy the printing as much as I did.
UPDATE initial
At the moment the installed motor is 12V/500RPM, but it is too weak. On order is 12V/100RPM. The slower motor has slightly bigger length of the gearbox, so there is a possibility that motor mount will have to be increased. I will post an update when I receive the new motor.
UPDATE 10.01.2020
Please let me know if there are any files missing as there are some issues with the file upload to Thingiverse.
Printer:
Modified FlyingBear P905X
Rafts:
No
Supports:
No
Resolution:
0.15mm
Infill:
10%
Filament: AzureFilm Strongman PLA Natural
Notes:
The part with needed supports is marked in the Trent 900 drawing.
There are two versions of N2 discs - one with brim and one without. I added brim as I was having issues with blades unsticking the print surface and ruining the print.
I have optimised the gap sizes based on my printer, so it is possible that you will need to do a bit more sanding to fit the parts.
The STL files are not positioned correctly, so you will have to position them on the bed yourself. As said, only one, marked part needs supports. Maximum overhang angle is around 55°.
For assembly I prepared detailed drawings which should guide you nicely through the process.
As the parts are optimised for 3D printing without support material, the assembly requires a bit more time.
It is highly recommended that you are very careful with assembly of the rotors and stators as clearance tolerances are very small.
Additional parts you will need:
Bearings:
4x 6704ZZ
4x MR126ZZ
1x 6805ZZ
2x 6700ZZ
MR85ZZ
6807ZZ
6702ZZ
6705ZZ
Recommended shop for bearings in EU is Kugellager-Express or AliExpress
Screws:
SPAX 2,5x10mm or similar (see Trent 900 drawing for details)
M3x4 (type does not matter much)
M6x15 DIN7985
M4x55 DIN965
M4x20 DIN965
M4x15 DIN965
Nuts:
M4
Aluminium rods (wall 1mm, see drawings for length):
Outer dimater 10mm
Outer diameter 15mm
Outer dimension 10x10mm
I got aluminium rods from the local hardware store, so they do not have any special tolerances.
Electronics:
2 pin male header
2 pin female header
Recommended tools:
Set of small files
Set of screw drivers (including PH000 bit for M1)
Epoxy glue (or your favourite glue for 3D prints)
Cordless power drill
Set of drills (recommended also 0,8mm diameter drill for holes where M1 is screwed directly in plastic)