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About Project

This intricately designed evaporator blower wheel, 3D printed in Nylon PA 12 using Selective Laser Sintering (SLS), showcases the power of additive manufacturing in functional thermal and airflow applications. With its radial blade configuration and centralized hub, the wheel is engineered to efficiently draw air across evaporator coils and distribute cooled air within HVAC or refrigeration systems.

Design Highlights

The wheel features:

• Thin, curved blades evenly spaced to maximize airflow efficiency and minimize noise.
• A central mounting hub designed for precision balance and motor coupling.
• A lightweight but robust construction suited for high-speed rotation and continuous use.

The open petal-shaped slots between the center and blade ring reduce weight while maintaining structural integrity, contributing to both performance and energy efficiency.

Why Nylon PA 12?

Nylon PA 12 is an ideal choice for this application due to its:

• High strength-to-weight ratio, which supports rapid rotation without deformation.
• Excellent thermal resistance, making it suitable for close contact with evaporator coils.
• Superior fatigue resistance, which ensures long-term performance under cyclical stress.
• Dimensional stability, even in humid or thermally variable environments – a critical requirement for HVAC components.

Additionally, SLS printing allows for support-free fabrication of complex geometries, enabling design freedom that traditional molding cannot match. This blower wheel likely integrates form and function that would be difficult to produce through injection molding without multi-part assembly.

Manufactured by FacFox

This part was expertly produced through FacFox's industrial SLS 3D printing service, leveraging precision equipment and high-grade PA 12 powders. Whether you're prototyping for thermal management systems or building low-volume production parts for air handling units, FacFox delivers reliable quality, fast turnaround, and engineering support every step of the way.

Explore FacFox's Nylon 3D Printing Service to bring your functional parts to life with strength, accuracy, and speed.

Solution

• Step 1: The 3D model of the evaporator blower wheel was designed using CAD software with optimized blade geometry for airflow performance.
• Step 2: The model was uploaded to FacFox’s SLS printing system and oriented for optimal strength and powder flow.
• Step 3: Nylon PA 12 powder was evenly spread across the build platform inside the SLS machine.
• Step 4: Each cross-sectional layer of the part was selectively sintered using a high-powered laser according to the digital model.
• Step 5: Once printing was completed, the part was allowed to cool within the powder bed to prevent warping.
• Step 6: The wheel was carefully removed from the surrounding unsintered powder, which was then recycled for future prints.
• Step 7: Post-processing was performed, including powder removal via media blasting and optional surface smoothing.
• Step 8: The final part was inspected for dimensional accuracy and mechanical integrity before being approved for use.
• Let me know if you’d like to include optional finishing steps like dyeing, sealing, or machining.