Over the past two months, the Savonius has gone through the last of its changes! I Toniann, the newest Industrial designer in the design team, have had the opportunity to design the final part of the Savonius Wind Turbine Kit. This will the first completely 3D printed STEM Kit from PicoSolutions! The design team has been working to convert all of our Educational STEM kits into fully 3D printable parts so we can move away from old injection molded parts, stay on track to becoming more sustainable, and so we can manufacture each piece ourselves in our Pico Studio space!
The final piece to the Savonius Kit was what we refer to as the S-foil. This is the part that catches the wind to spin the Rotor Disk below it which houses the magnets, this spinning over the copper coils in the base will create enough energy to power an LED.
Originally made out of die-cut metal, the S-foil needed an upgrade. See how it looked before, below is an image of our old design, the blue part is the previous s-foil:
Old S-foil Design
The S-foil has since gone through various iterations to convert it into parts that can be printed on our WASP 3D Printer without the use of support material (No waste plastic here!). From the start, I worked to create a similar shape and design as our previous model had looked. These parts have to allow the foils to connect to each other and the axel as well as be sturdy enough to be able to be taken apart for multiple uses. We came to our first option of having two identical parts that can connect together. Utilizing dovetail joints and specific design to create the hole for the center axel when the two parts lock together. Making adjustments along the way like trimming it down the center connections and making adjustments to the width. Check out the first three iterations below:
Version 1 -3 in order from Left to right
After getting to this point we realized that this design allowed for zero modularity. How are you gonna teach how it works if you can't show different versions and their results. We wanted the option to test out more or fewer foils. We also wanted the user to have the option to get involved in creating and designing their homemade foils to test in the classroom. With that in mind that's how we came to the final design below:
Final S-foil Design
Allowing up to four fins, connected to the center axel by a connection chip in the center which creates a modular s-foil. Having connection caps at the ends to keep all the parts sturdy while spinning. Allowing you to add and subtract removable fins to test the power based on the amount of wind caught by the s-foil.
I am very happy about how this came together please let us know how you like it! This is just the first kit in our goal to have all of our products to be completely 3D printed! Keep checking in to see what we are up to next as well as other exciting posts and updates from our team!