Uploaded August 2016 | Updated September 2026, 2 weeks ago

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In this video I'll take you through my step-by-step procedure for 3D printing an airfoil.

We start with the creation of a coordinate file in MATLAB, which is essentially just a list of X and Y data points that describe the shape of the airfoil. Then we load the resulting Excel file into Inventor, and make the model that we want to print. Then we export the model as an STL file and load it into Slic3r, where we get the printing orientation correct, along with the actual printing instructions/settings. Finally, we print the airfoil!

NOTE 1 (Time = 0:30)
For this particular print, because it was so small, the trailing edge ended up being just a single line thick (one pass from the extrusion nozzle). This means it wouldn't have mattered if I had left this as 'closed'. For big enough airfoils, you will be able to notice a difference.

NOTE 2 (Time = 7:01)
I leave the infill as 20% here, but because the airfoil was so small to begin with, it just filled it in solid, as you can see when I go to the Layers tab at around 7:40 and scroll through the layers.

NOTE 3 (Time = 15:50)
I get a little jittery when I see that the plastic isn't sticking immediately, so I slowed it down. It might have been fine without me slowing it down. There's a chance that I would have gotten a better bottom edge on my airfoil (as you'll see me complain about after the print is finished). You'll also see me messing with the speed throughout the sped-up video in a second. I'm going to stop interfering with these prints in the future, as it might be making things worse.