Development of a regenerative pump impeller using rapid manufacturing techniques

Purpose The purpose of this paper is to present a method of rapid prototyping (RP) used in the development of a regenerative pump impeller. RP technology was used to create complex impeller blade profiles for testing as part of a regenerative pump optimisation process. Regenerative pumps are the subject of increased interest in industry. Design/methodology/approach Ten modified impeller blade profiles, relative to the standard radial configuration, were evaluated with the use of computational fluid dynamics (CFD) and experimental testing. Prototype impellers were needed for experimental validation of the CFD results. The manufacture of the complex blade profiles using conventional milling techniques is a considerable challenge for skilled machinists. Findings The complexity of the modified blade profiles would normally necessitate the use of expensive computer numerically controlled machining with five‐axis capability. With an impeller less than 75 mm in diameter with a maximum blade thickness of 1.3 mm, a rapid manufacturing technique enabled production of complex blade profiles that are dimensionally accurate and structurally robust enough for testing. Research limitations/implications As more advanced RP machines become available in the study in the coming months, e.g. selective laser sintering, the strength of the parts particularly for higher speed testing will improve and the amount of post processing operations will reduce. Practical implications This technique offers the possibility to produce components of increased complexity whilst ensuring quality, strength, performance and speed of manufacture. Originality/value The ability to manufacture complex blade profiles that are robust enough for testing, in a rapid and cost effective manner is proving essential in the overall design optimisation process for the regenerative pump.