100mm Aerodynamic Propulsion System (Ducted Fan Assembly)

About this project

Project Overview This project features the complete design and parametric optimization of a high-efficiency 100mm Ducted Fan Propulsion System engineered for UAV and VTOL applications. Designed in SolidWorks, the assembly prioritizes streamlined airflow, structural rigidity, and tight mechanical tolerances across rotating and stationary components. Key Technical Features • Optimized Inlet & Shroud Geometry: Features a prominent 20mm radius elliptical bell-mouth inlet to minimize boundary layer separation, transitioning into a rigid 5mm constant-wall section and a converging exit nozzle to accelerate thrust velocity. • Aerodynamic Tail Cone: A 50mm tall tail cone defined by a smooth 130mm radius curve to reduce wake turbulence and drag at the exhaust exit. • Precision Fit & Clearance: Engineered with a 4.00mm radius (8mm diameter) bore on rotating parts (Rotor Hub & Nose Cone) for secure shaft mounting, paired with a 4.50mm radius bore on stationary components (Stator Pod & Tail Cone) to maintain a frictionless 0.50mm air gap. • Structural Stator Stage: Integrates 2.00mm thick exit guide vanes to bridge the core pod to the main duct while removing airflow swirl to maximize directional force. Software & Methods • CAD Software: Dassault Systèmes SolidWorks • Techniques: In-Context Assembly Modeling, Parametric Surface/Solid Lofting, Circular Patterning, Mechanical Fit Optimization Full case study available on Behance: https://www.behance.net/gallery/255227805/100mm-Propulsion-System-(Ducted-Fan-Assembly)