Evaluating aerodynamic characteristics of wind-tunnel models produced by rapid prototyping methods

Initial studies of the aerodynamic characteristics of proposed launch vehicles can be made more accurately if lower-cost, high-fidelity aerodynamic models are available for wind-tunnel testing early in the development phase. The results of a study undertaken at NASA Marshall Space Flight Center are discussed to determine whether four rapid prototyping methods using a variety of materials are suitable for the design and manufacture of high-speed wind-tunnel models in direct testing applications. Also presented is an analysis of whether these materials and processes are of sufficient strength and fidelity to withstand the testing environment. In addition to test data, costs and turnaround times for the various models are given. On the basis of this study's results, one can conclude that rapid prototyping models show promise in limited, direct application for preliminary aerodynamic development studies at subsonic, transonic, and supersonic speeds.