Challenge
Our client required six fan blades for a new chemical fume extraction system. The blades needed to match the existing geometry precisely to maintain airflow performance, efficiency, and system compatibility. Additionally, the components had to withstand a corrosive environment while operating reliably at speed, with minimal vibration.
Solution
We reverse engineered an existing blade to accurately capture its geometry and aerodynamic profile. Using this data, detailed CAD models and flat patterns were developed for manufacture.
All components were cut in-house using our Fibre Laser Cutting service to ensure high dimensional accuracy and repeatability. The blade sections were then formed using our in-house rolling processes to achieve the required curvature and surface consistency.
Each blade was assembled and TIG welded into position using controlled procedures to minimise distortion and maintain alignment. Upon completion, the full assembly underwent dynamic balancing to ensure smooth operation and reduce mechanical stress on the system.
Result
The finished fan blades provided a precise match to the original design requirements, ensuring performance and efficiency. The use of stainless steel improved corrosion resistance and service life, while accurate balancing ensured reduced vibration and reliable operation.
