Challenge

A high-volume industrial product required bespoke fan designs capable of delivering the required aerodynamic performance while achieving demanding efficiency, acoustic and production-cost targets.

Engineering Approach

Two fan configurations were developed: a vane-axial fan and a backward-curved centrifugal fan for the higher-pressure application. The aerodynamic designs were developed using first-principles analysis and mathematical modelling. Structural and vibration FEA were used to assess mechanical integrity, fatigue resistance and dynamic behaviour. The blade and housing geometries were developed specifically to allow manufacture using two-part injection-moulding tools, avoiding more complex tooling and reducing production cost. Experimental testing included resonance measurement using accelerometers and evaluation of acoustic performance. A purpose-built ducted pressure-flow test rig was also designed and constructed to characterise the aerodynamic performance of the fans.

Outcome

High-efficiency vane-axial and backward-curved centrifugal fans were successfully developed for the application, achieving aerodynamic efficiencies exceeding 85% while meeting the required acoustic performance targets. Both designs were engineered as injection-moulded components suitable for high-volume production, combining aerodynamic performance with cost-effective manufacture.