The use of rapid prototyping (RP) techniques, such as stereolithography, is proposed for the low-cost, rapid-turnaround manufacture of ready-to-test turbomachinery test hardware. The authors of this proposal were responsible for two recent test rig programs in which stereolithography was used. In one program a turbine rig model to test CFD design methodology for the Space Transportation Main Engine (STME) turbopumps, stereolithography rotating models of actual hardware were produced to test different inlets under low-speed conditions. This helped to identify design improvements but could not be used to greatly impact on the actual cost of generating testworthy hardware. In the second, a turbopump rig program for deep space mission rockets (AETB), pump impeller models were manufactured for visualization of designs and generation of tooling. The purpose of this proposal is to explore and improve the state of the art of the materials and manufacturing methods to reduce the time and cost of designing and fabricating highly instrumented turbomachinery test rigs. The Phase I effort will be directed at the choice of materials and improved manufacturing techniques. Phase II effort will be to fabricate a suitable, workable, test model making optimum use of these new materials.
