3d Printed Turbofan Engine

Hello guys, I needed a break away from the motorised throttle build and for the first time in my life decided to point somebody else's design. What a design to start with! It's awesome and I have learned so many new techniques for my designs. This was aviation geekery at its best. Im amazed with what a 3d printer can do and almost want to push this engine past its limits!
The Full Design and STL's can be downloaded here for free:
grabcad.com/library/high-bypa...
The original core engine here for free:
www.thingiverse.com/thing:132...
A massive Thank You to Sebi Woelke for the Intro and Logo!
If you would like to help support the channel and the build, our Patreon link can be found here:
PATREON
A couple of people have asked if I have a Patreon account, I finally got around to creating one. If you fancy showing support for the videos and build, and I have switched off advertising for videos now:
/ 737diysim
The plans/designs/cad and wiring diagrams are available at WWW.737DIYSIM.COM.
Facebook: Boeing738v2
Instagram: 737DIYSIM
Music audio library License: Chris Haugen - Fresh Fallen Snow

[@chrisshakal5904]

Hey, thanks for printing this, and thanks for the shout-out! The nacelle cowlings really do take the design up a notch, don't they?

[@helimech8152]

Hello Chris! You Sir are a legend and a warm welcome from me here in Brunei. Great to hear from the designer, and what a design that was! So cool LOL! Very well done and very clever! The whole thing now stands on my desk and will feature in the background of many videos hopefully. I have only just found you on Thingiverse and linked your design there too. Thank you for taking the time to drop by and say hello. Kind Regards Karl.

[@paint_dude]

Hello Chris, this masters peice of a design. With your permission I would love to build it out to build it and actually power it. We are hoping to build the first jet powered aircraft in Nigeria 🇳🇬. This is a huge inspiration

[@timothycatchpole7948]

Chris, do you have a design for the fan stator casing, compressor casing, turbine casing, etc., in two halves that can be assembled together to create a 360 enclo sure??

[@realitypreferred7084]

@@timothycatchpole7948 Hi, did you get a reply or did you find them? The Thingiverse files don't show these files, as far as I can find.

[@kacpernowotynski6699]

Because of this video, I ended up printing one as well. Took over a month with my single printer and printing my last chevron thrust reverser piece as I type this. Less than 24 hours on print left. Thanks for the awesome video Karl!

[@helimech8152]

It's a fantastic, fun build! Enjoy and at the end you will have a gorgeous piece of aviation art!

[@AlphaFloor320]

It's cute to see when you are assembling it, you have stars in your eyes ^^

[@rickestabrook4987]

Karl, you've outdone yourself. Fantastic. And there's no way you can say "Cool" too many times with this thing. THANKS

[@helimech8152]

Hi Rick, it was nice to get away from the pressure of building my designs and just going with somebodies else's design. So much fun and I think it shows I the video. Thank you.

[@NeonAstralOfficial]

This guy has a great smile and is very interesting to listen too

[@helimech8152]

Thank you for the kind words, Karl

[@zlm001]

This is amazing. I have been looking for a great model of a turbofan engine and there are NONE that are any good. This is perfect! Thank you.

[@zlm001]

I can't express how awesome I think this is. Thank you so much for making and videotaping the build. I wish I had the message to make one. Amazing.

[@helimech8152]

Hi Zach. You are so welcome and thank you for the kind words. Best regards Karl

[@tomhofmann5277]

Hi Karl! I’ve been just lurking around for many many episodes. I enjoy them not only because of the stupendous engineering and handicraft but because you have a wonderful and engaging personality and a permanent smile! I enjoyed this build tremendously and I am fighting the urge to build one myself. Please keep doing what you do! All the best from Argentina.

[@helimech8152]

Hi Tom, hello from Brunei, thank you for taking the time to comment and the kind words are much appreciated. Put a smile on my face. Thank you and kind regards Karl

[@Dragonus1979]

Absolutely Awesome Karl! 3D printers are becoming one of the most amazing tools. You think of something, and it becomes real! I thoroughly enjoy your video's mate!

[@helimech8152]

Hello Sir, thank you for taking the time to comment and the kind words. Kind regards Karl

[@doverivermedia3937]

Wow. Superb job there ! Reminds me of Happy days in Derby during my RR apprenticeship many moons ago. Thanks so much for sharing a great project ! ... 🇬🇧

[@humor62]

Fantastic job! This is by far the best video I have seen all year, makes youtube worth watching again! SUPER COOL!!

[@helimech8152]

Humbled by your words, thank you! Kind regards Karl

[@JeanMarieEsc]

Magnifique turboréacteur. C'est littéralement un travail de fou. SUPERRRRRRR GEANTTTTTT !!!!

[@helimech8152]

Merci beaucoup pour les gentils mots et d'avoir pris le temps de passer et de commenter! Cordialement Karl

[@phillipzx3754]

My definition of "working" must be different. I was expecting something that burned fuel and was functional. Cool model.

[@helimech8152]

I get this comment a lot, in my trade I would have said operational if it was going to burn fuel. Working as it demonstrates the internal workings of the engine. But yes, regardless, its a beautiful model that Bob and Chris created. Kind Regards Karl

[@C-M-E]

@@helimech8152 While a title change probably wouldn't fetch as many views, "3D printed interactive cutaway jet engine" would snag more keywords and be a bit more honest.

[@jimmyjames1807]

it all so says 3d printed, do u seriously think u can a jet working if its 3d printed

[@jimmyjames1807]

@@emptymannull 110% is impossible, cant go over 100%, numbnuts

[@C-M-E]

@@jimmyjames1807 Why would something being 3D printed preclude it from being a functional part? Different manufacturers can print some version of everything '3D' now, from houses to organs to jet and rocket engine parts, and you'll find them more than suitably functional.

[@MJ-iy4fb]

Fantastic build. The amount of effort is amazing. Nice work.

[@helimech8152]

Hello MJ, Thank you very much for those words. Kind Regards Karl

[@tomcat5198]

It’s not just the turbo fan that’s a master piece it’s the whole channel!

[@helimech8152]

Hello and thank you! Kind Regards Karl

[@HDJess]

Challenge for you: build steel replicas of every piece and try to actually start it with kerosene :)

[@jkvdv4447]

I was also waiting for the "working" part..

[@helimech8152]

After seeing the rocket engines that are now 3d printed metal, I do wonder if this is possible. But I'd need a few more people watching my vids, before that becomes a reality!

[@krystalbrooks6869]

@@helimech8152 this is my first day.

[@AdmiralCrunch01]

@@helimech8152 dude thats a must, seeing that work would be phenomenal

[@SH-uv5kv]

​@@helimech8152 Put the "Thanks" button so that people can donate.

[@brianhiles8164]

In the early 90s, the traveling Smithsonian exhibit -- you know, the Hope diamond, Lincoln´s 10-gallon hat, Dorothy´s shoes, and a Moon Buggy, came to town, which I was happy to visit. What _really_ blew my mind, though, was a slowing rotating _perfect_ quarter scale model of a commercial turbofan engine at the egress of the exhibit. I have come to realize this as one of the first examples of additive construction. The model was even sized to incorporate thousands of titanium bolts -- a quarter the size as those actually used. Wonderful!

[@helimech8152]

Hi Brian, I would have lived to see that! This is just a plastic version, but I'm so impressed with it. 3d printing is moving fast!

[@prestoncooksey5925]

I love the colors you used for the casing body and stators. I ordered Metallic PLA to try to match all the colors you're using and I'm printing the pieces now. The Bamboo P1P is churning these prints out fast. This video is very inspirational. Great job!

[@helimech8152]

Thank you, This is such a fun build and brings back many fond memories. I can only imaginbe the quality of the prints on the X1! Have fun with this one!

[@thehighwayman78]

What an incredibly beautiful display piece!

[@helimech8152]

Thank you, the designers did an awesome job on this!

[@thehighwayman78]

@@helimech8152 They made an awesome kit! And you did a fantastic print and build of it! How much PLA / resin did the build consume?

[@therogerchip]

Un gran trabajo. Felicidades

[@zlm001]

This is still a dream of mine to build this model. Thanks again for building on others work, building it, and putting it together. I love turbofans and don't understand why stuff like this isn't available.

[@helimech8152]

Hi Zach, this was a fun build. Funny, I was just packing this up last night ready for our move back to the UK.

[@zlm001]

I think my original reply was auto deleted by KZbin, I'll try again but separate them into multiple replies as I have a guess as to why a program would auto-delete it.

[@zlm001]

Special Note: I applied for a 3D printer very quickly before work began today. I may have not remembered the details accurately about original build and I don't tweet anymore, so it's a mess of replies to replies. If you are unhappy with my tweets for printer for any reason whatsoever, or just simply don't think I should apply with that goal, or have any other issue, just let me know and I will delete the tweets as soon as I can after seeing your deletion request, if it is made.

[@zlm001]

I really do love this build, you went above and beyond in creating it. Most of the few models that exist don't have a cowling or pylon, which I think adds so much to the aesthetics and feeling (well, looking at it on screen feeling). I'm still surprised or shocked you can't get a proper model of one (I really wanted one of the iconic GE-90) as I just love Turbofans for some reason. They just get me going, always. And since no one offers it, I decided I'd slowly learn the things necessary to build one myself based on yours and your inspiration sources. At current rate it will be a long while. I've been getting better with electronics, but got slowed down by my own recent moves. Next step is a 3d printer, so full disclosure, I applied for a 3d printer (reason for new comment was I had to find your original video to credit) with stated goal of printing a model similar to yours. Even if I don't get to make one as great as yours I'm just happy someone did it and took the effort and time to record it and share it with the world. Good luck with your move, hope it goes smoothly, but box that project well, it's super unique and something that should bring you great pride.

[@zlm001]

You can find the tweets by searching at Morbo on Twitter, but be careful when searching. I wanted the Futurama name MorboTheAnnihilator, but it was too long, and now I have yet to figure out if Morbo means something in another language or Twitter is just deranged.

[@Bedgie01]

Now you need to print another one, then attach them to either side of the sim. Or even better hook them up to the sim so when you do an engine start they spin that way you can confirm engine start.

[@helimech8152]

That sir is a very cool idea!

[@kodywillnauer9422]

Or even enlarge the print % and go 1:1 of the real thing!

[@MobiFlight]

That would be awesome! I was thinking the same thing !

[@keemoosabi8350]

What can I say……. Just amazing as always 👍🏻👍🏻

[@helimech8152]

Thank you so much 😀

[@nuttybuddy719]

Thanks you showing a great build that's so cool .now time for powering it up.

[@helimech8152]

Any time and thank you for taking the time to comment.

[@stevegolden6480]

Absolutely brilliant !

[@helimech8152]

Thank You!

[@tombuglewicz8020]

Love it, great work!

[@ferhatsogukkuyu6768]

DUDE, THE VIDEO AND ITS CONTENT ARE VERY GOOD. I've watched many videos since KZbin was launched, but this was the best of the thousands of videos I've watched. Thank you very much. Ankara and Ferhat Sogukkuyu

[@oddjobbob8742]

At 22:10 the bronze colored fan(?) looks so beautiful spinning so smoothly. It looks so reflective. Thank you for sharing this build.

[@helimech8152]

Hello and thank you for takingbthe time comment! Kind regards Karl

[@friedchicken1]

Man, this is cool beyond repair

[@helimech8152]

Hello, and I agree! Too cool for Skool!

[@oogityboogity6644]

Imagine an rc plane with just two of those, absolutely nuts

[@benjaminthurston6215]

This video is very well done. Wonderful job.That said, it would be astounding to hear you say: "Well, this one goes to 11". Cheers!

[@helimech8152]

Thank you very much! Next time! Kind Regards Karl

[@Sirmellowman]

holy crap thats so freaking cool!

[@helimech8152]

Well that made me smile! Indeed...Cool! Kind Regards Karl

[@johnnie135]

Wow.., 3D printing is the future for sure. Case in point: Your amazing Turbofan engine. Well done! 5 Stars.

[@helimech8152]

This was done on a CR10, id love to see the quality on newer machines like the Bambu! Thank you for the kind words.

[@hafeezminhas]

That look gorgeous. Love every detail of it. Now I wonder what would it take to build every single part of a real engine and assembling it to precision.

[@helimech8152]

Hello, ill leave that job to the professionals like Rolls Royce & General Electric! It does make for a great show piece though. Kind Regards Karl

[@707liner8]

Wow, that is superb!

[@helimech8152]

Thank you! It's a cool bit of kit!

[@patrickg875]

Truly, it is an excellent build. I have built and still working out some details. I created a detailed accessory package and a swiveling undershelf mount along with 3d lights and a faster 2000 rpm motor. I love this Trent 900 design. Pay the $15 to WileyRC and get the functional reversethrusters. It's amazing!

[@helimech8152]

Hi Patrick, This was just for a Prop in the background. Loved the design and build. However, since making this video, i know have turbo prop engines, helicopter gearboxes to create, the list is growing fast. My place will look like my old college training room with all the parts of 3d printed aircraft components. Kind Regards Karl

[@shagmesilly78]

That is so bloody cool. I'm definitely going to print this :)

[@helimech8152]

Hello! I can't recommend this design enough!

Genuine happy guy... nice to watch along.

[@helimech8152]

This was a very fun build. one of my favourites.

[@sukrudemirci3139]

Wonderful work.

[@helimech8152]

Thank you so much 😀

[@hefeibao]

That's beautiful, that is.

[@helimech8152]

Hello and thank you! Kind Regards Karl

[@DanFrederiksen]

Very nice. Imagine it printed on a very precise metal process and it actually worked :)

[@isfj1009]

WOW! That is really cool!!!

[@helimech8152]

Thank you! I think so too! lol Kind Regards from Brunei.

[@coryturner9140]

I would love to build one of these, so cool!!

[@helimech8152]

Hi Cory! This was such a fun build and i loved every moment as an aviation enthusiast!

[@QuantumCoinConnect]

beautiful work brav thank you.

[@helimech8152]

Thank you too! & kind regards Karl

[@ofonwilliam]

This is super cool,thanks for the free files

[@helimech8152]

Thank you, the files are courtesy of the designers Bob & Chris. Kind Regards Karl

[@ashims1983]

Very interesting! Thanks a lot. from Japan.

[@helimech8152]

Thank You from Brunei! Karl

[@dyoox01]

This was amazing. Subscribed!

[@helimech8152]

Welcome aboard! and thank you, Kind Regards Karl

[@NickSmith-hv9zi]

Brilliant. Brings joy to see good quality prints. "Aviation geekery" :) lol

[@helimech8152]

Thanks Steve!

[@SajanaYasas]

OMG, It is amazing. Keep it up.

[@helimech8152]

Thank You! Kind Regards Karl

[@jamiesss7085]

Incredible !!!

[@sirmontecristo2808]

That's so cool.

[@a330turbinex7]

Superb!!!

[@zlm001]

So awesome

[@ThegoodOutlook]

Nice, very interesting educational video. Keep it up, mate!

[@helimech8152]

Hello and thank you! Kind Regards Karl

[@Fenixking307]

Your accent is so good. I hope you become the big channel you deserve.Greetings from Turkey.

[@helimech8152]

Hello and greetings from Brunei! Thank you

[@djkatz7821]

Been waiting for this video!

[@helimech8152]

Hey Josh, what did you think. It made me smile building it! It's so cool! Lol

[@mick-tf7xj]

Love it ,thanks Karl !

[@helimech8152]

Hi mick! Thank you! All good at your end? Still smiling and healthy as can be?

[@mick-tf7xj]

@@helimech8152 as much as it can be thanks Karl

[@srinivasvaranasi1645]

Enjoyed it!

[@helimech8152]

Thank You.

[@guyhermann9547]

Super cool!

[@user-qz2sh4ss8f]

wow~ thank you

[@sorry4all]

Great quality

[@helimech8152]

Thank you!

[@richardbriansmith8562]

Awesome can't wait to see it work with a motor

[@helimech8152]

Hi Richard, I'm currently looking for speed controller and motor that will achieve at 8000 rpm

[@richardbriansmith8562]

Awesome can't wait to see it running again.

[@ShichaoChenhongyu]

Cool! I like it.

[@davidmartineziii7343]

That's so neat ^_^ something about engines is just fascinating! I've been looking for my next big 3D printing project to do also! Last summer my big build was the Subaru EJ20 boxer engine, and it was a real journey. It really tested me and my DIY 3d printer just as much. This model is definitely on the tentative list :-D

[@helimech8152]

I can't recommend this enough. It looks stunning on the shelf, and even better fun building it.

[@TheTomCruiseLover]

Great USB desk fan!

[@helimech8152]

I love it!

[@idramirezs]

QUE HERMOSO TRABAJO FELICITACIONES

[@helimech8152]

¡Gracias! Saludos cordiales Karl

[@PhG1961]

Cool video. Nice workshop btw.

[@helimech8152]

Hi Philip, Thank for the awesome comment. Kind Regards Karl

[@frankkky7375]

this could be a new type of puzzle for aviators....

[@helimech8152]

Its a great build and certainly a bit of a puzzle if you dont read the instructions! lol

[@raywalsh5414]

As well as making amazing kit, you also make great videos. You should do a video on video production sometime !

[@helimech8152]

Hi Ray, I am very much learning the video front. There really is so much to learn and i now appreciate people who do this for a living!

[@ConcordeError404]

Damn, looks pretty good, can send this off as an Prototype of the RR Trent 1000 and no one would notice

[@helimech8152]

It still makes me smile now when I look at it. The designers did an awesome job .

[@vyacheslavdernovoy7044]

Good job!

[@helimech8152]

Thanks!

[@reginaldcrudstump383]

Karl, this is amazing. Can you do a video describing your SLA printer setup as I see you have a few machines there in the corner.

[@helimech8152]

Hi, i have 2 3d resin printers. The Creatilty LD002R wins over Elegoo mars easily in my opinion. The other ones are a wash machine and curing unit. I will certainly try to create something in the future once the throttle unit is done. Kind Regards Karl

[@deathblowhere]

Haha, that's sensational, Karl! Thumbs up! Next you should print throttle quadrant of same scale and connect em together! :D PS. Attaching vacuum cleaner's motor at the end will give almost real sound as well! :))) All the best, Phil.

[@helimech8152]

Cool idea! I need to strengthen the large turbine blades first. The stress of more rotational force and i can see it ripping itself apart. However, since building this, many other 3d printed engines have now popped up on my radar that have designed with extra speed in mind.

[@Never_quit]

“That’s never gone go in” 2 seconds later “ perfect fit” 😂

[@Jer29]

Hey! Awesome build! Question. Where did you get those L shaped hinge pins to keep open the engine doors??

[@revotrucksimulator]

Muito legal...quero um desse...

[@helimech8152]

Super cool!

[@fabiobarros5318]

Wow, I just realised that I'm view and reviewing your videos and not gave a like and subscribed. I'll do this now!

[@GowitChaimongkol]

This guy is genius an engineering

[@helimech8152]

Thank you, This design belongs to Chris and Bob. They are the geniuses behind it.

[@mikemike6096]

Very nice! I'm deciding if I want to commit to this build. Only take about a month printing it out on my Ender3, lol.

[@helimech8152]

If you love aviation then yes! Its truly amazing and such a fun build. Go for it!

[@StigBSivertsen]

Just amazing :-)

[@helimech8152]

It's cool lol, but the designers deserve the credit for this one. Kind regards Karl

[@faridlarkem8225]

Genius, wow.

[@helimech8152]

Very! There ate some very clever people out there.

[@bhawanisinghindia2287]

amazing work ...👍👌✌🙏🌹🤝🌍🌎🗺👽🤖

[@helimech8152]

Thank you! Cheers!

[@user-bo5sv8ni9h]

good job👍

[@helimech8152]

Thanks for the visit and taking the time to comment. Kind Regards Karl

[@bobmichael190]

Smart technologies for smart people.

[@helimech8152]

Hello, To be able to make this at home by primarily pushing a button is fantastic. 3d printers have helped produce parts i could only dream of when regarding the full sim build. Kind Regards Karl

[@UncleKennysPlace]

We print metal parts for actual turbines where I work! This is a lovely model.

[@helimech8152]

Hi Kenny, great to hear from you. I enjoyed building this model, it took me back to my apprenticeship training days of looking at cutaway gas turbines.

[@helimech8152]

Hi Kenny, great to hear from you. I enjoyed building this model, it took me back to my apprenticeship training days of looking at cutaway gas turbines.

[@loomex]

Love it! We grind and mill turbine blades and vanes where I work. (a lot of P&W, Vericore and Honeywell parts)

[@DaveWrightKB9MNM]

So I started my build yesterday. Bearings are in the works as we speak. Question: what filament did you use for the trim ring on the front of the intake? If not, did you cover it? Im working on the Nozzle Assembly now, should be finished today.

[@donaldburkhard7932]

There is stool to scrape off edges, it turns to follow contour. Also magnetic extendable tool for screws. Put graphite between rotating parts and casing so spin easier and not heat up as much.

[@helimech8152]

Hi Donald, thank you for the advice! Kind Regards Karl

[@kekelinks]

Did you know that for some of the airbus airplanes , a few engines are attached to the wings by just 3 bolts ? I used to manufacture some when i was working in an aerospace related company. When I discovered that it blew my mind.

[@rtwileyrc8030]

The Trent 900 that this 3D printed model depicts is one of those. There are only three “bolted” attachment points to the wing. There is a forth vertical pin from the wing that goes into the pylon but only constrains the thrust of the engine. It supports no weight whatsoever and does not need to be detached to remove the engine. The three bolts are also not solid connections but are actually pivot points themselves. All this is done to carefully distribute the weight, aerodynamic loads, and thrust of the engine to the wing structure without generating additional parasitic stresses. This 3D printed model has four bolt attachment points but there would be additional brackets that go between these attachment points and the three bolted connections on the wing. The socket for the vertical thrust pin is modeled in the pylon. Some builders of this 3D model have gone as far as modeling the additional brackets and basic wing structure to attach the engine model.

[@simuladordevuelomexico467]

Amazing !!!!!

[@helimech8152]

Thank you

[@nathd1748]

Holy Batman!!!

[@DavidFunk4475]

This awesome piece is on my build list. But question for you, what is that blue work surface that you're working on? Those compartments look ideal for holding small parts.

[@helimech8152]

Its an amazon Blue work mat silicon. Just type that in and you will see hundreds!

[@JM-wi8xe]

You will have a 737 printed next karl!!! Brillant.

[@helimech8152]

That was actually what I was looking for. I wanted a display model.in the background. But I couldn't find one. Kind regards karl

[@therealityartist9057]

And also are these machines capable of making anything no matter how difficult and complex it is

[@timfurtado]

awesome!

[@helimech8152]

Thank you

[@krystalbrooks6869]

Nice build. I've been looking for a 3D printed GE9X engine for the past couple of days. This is a big build. Did the air become restricted after you ran it fully assembled? How much cfm do you think the engine produces?

[@helimech8152]

Hi, at 2000 rpm not much, but enough to feel it. Someone else just mentioned driving it with compressed air. That would really spin it up, but destruction would soon follow after.

[@skesinis]

Amazing model of a turbine!! I was wondering if teflon spray on the parts that still have some friction, would make it run smoother.

[@helimech8152]

Hi Sophoclis K, When the design was created, I wouldn't imagine there were many Resin printers available 5 years ago. If I had printed all the parts with a filament printer, I think it would have been super smooth. With a resin printer, my parts come out 0.4mm bigger in diameter. This caused friction against the filament casings. However, Chris the designer actually designed the rotors with wear rings. So as the unit was rotated more and more these wear rings bedded in and the friction reduced. I also need to replace those 3d printed bearings with new steel bearings. This should also improve the running of the unit.

[@skesinis]

@@helimech8152 My first and very brief experience with a 3D printer was with a raisin one, about 11 years ago but it was so expensive at that time, it would make it impossible to own one. I was so impressed back then, even with the simplest sample: a ball embedded in a nut with a spherical cavity, which would make it impossible to be created as two separate parts and then put them together as such. Since then, 3D printing has become much more affordable, but still what people can do with it still amazes me! That jet engine model is a marvel and I’d really like to see a video when you’ll have all the things that you mentioned sorted out!

[@Wolfr4mium]

You almost got me when you said "Working" hahaha

[@defender3330]

Lovin that Karl

[@helimech8152]

Cheers!

[@contigo121]

It's been absolutely fascinating and educational seeing you put this model turbofan jet engine together from scratch (so to speak). It's given me a much greater insight into it's inner workings aided by your jolly enthusiasm.

[@helimech8152]

Thank you very much! I did enjoy this build! Kind Regards Karl

[@gr8motive]

Cool!! May i ask what filament used here is?