Executive Summary

This project presents the complete parametric design and aerodynamic development of a high‑efficiency 100 mm Electric Ducted Fan (EDF) propulsion module intended for UAV and VTOL platforms. Built entirely in SolidWorks, the system emphasizes static thrust generation, smooth induction airflow, and precise mechanical tolerances across all rotating and stationary components. The design integrates optimized blade geometry, a refined bell‑mouth intake, a converging exhaust nozzle, and structurally robust stator vanes to deliver a compact, high‑performance propulsion unit.

Core Aerodynamic & Structural Features

Rotor Stage & Blade Geometry

The rotor features 18 aerodynamically contoured blades arranged around a central hub.

• Blade span: 30 mm (20 mm hub radius → 50 mm tip radius)

• Blade thickness: 2 mm at the root

• Profile: Progressive twist to maintain uniform axial velocity This geometry ensures efficient swirl generation while minimizing tip losses and maintaining structural rigidity.

Optimized Duct & Bell‑Mouth Intake

The intake transitions from a standard cylindrical profile into an asymmetric aerodynamic duct.

• Bell‑mouth radius: 20 mm This smooth curvature reduces induction turbulence, prevents flow separation, and improves mass flow rate into the rotor stage.

Converging Exhaust Nozzle

The shroud maintains a 5 mm constant wall thickness and tapers into a converging nozzle at the exit. This geometry accelerates the airflow, increasing dynamic thrust and improving overall propulsion efficiency.

Aerodynamic Tail Cone

A streamlined tail cone with a 50 mm axial height and a 130 mm arc radius eliminates base drag and stabilizes wake flow behind the stator pod. The profile ensures laminar exit flow and reduces vortex shedding.

Precision Mechanical Fits

Rotating components (nose cone and rotor hub) use a 4.00 mm radius press‑fit bore for secure shaft engagement. Stationary components (stator pod and tail cone) incorporate a 4.50 mm radius bore, maintaining a 0.50 mm air gap to eliminate friction and prevent contact during operation.

Flow‑Straightening Stator Vanes

The stator pod is supported by 2 mm thick structural vanes that:

• Straighten swirl from the rotor

• Convert rotational momentum into axial thrust

• Provide high rigidity under load

Technical Specifications

Parameter Value

Fan Inner Diameter 100 mm

Blade Count 19

Blade Span 30 mm

Blade Thickness 2 mm

Rotor Hub Diameter 40 mm

Duct Wall Thickness 5 mm

Bell‑Mouth Radius 20 mm

Stator Vane Thickness 2 mm

Rotating Bore 4.00 mm radius

Stationary Bore 4.50 mm radius

Tail Cone Length 50 mm

Tail Cone Arc Radius 130 mm

Design Methodology

The propulsion system was developed using advanced SolidWorks techniques, including:

• Top‑down parametric assembly modelling

• Fully constrained sketch relations

• Aerodynamic lofting and surface blending

• Circular patterning for rotor blade distribution

• Mechanical clearance and tolerance optimization

The design targets high‑speed UAV propulsion, VTOL thrust modules, and compact aerospace duct research applications. Future iterations will incorporate CFD flow validation and FEA structural analysis to refine aerodynamic performance and structural reliability.

Project Conclusion & Design Value

The 100 mm Aerodynamic Ducted Fan Propulsion System represents a fully parametric, CAD‑driven design focused on aerodynamic geometry, structural clarity, and manufacturability. Every component from the 19‑blade high‑solidity rotor to the bell‑mouth intake, stator pod, and tapered tail cone was engineered using precise dimensional constraints, fit tolerances, and assembly logic to ensure reliable integration with UAV and VTOL propulsion modules.

This phase of the project is intentionally limited to CAD modelling and mechanical design, with no CFD, FEA, or acoustic analysis performed yet. However, the geometry, clearances, and structural layout have been developed to support future simulation workflows. Upcoming stages will include aerodynamic CFD validation, structural FEA refinement, and aeroacoustics performance assessment to further optimize thrust output, reduce losses, and evaluate noise characteristics