Thank you for your interest in the SkyersJet project. Here I will discuss some of the design ideas behind it.
Typically, the manufacturing methods used to produce EDFs are 5-axis CNC machining, injection moulding or carbon fibre laminate forming. These methods are all very expensive, which is why any EDF of size 200 mm and above tends to cost thousands.
Fortunately, low-cost consumer 3D printing machines are available nowadays which are capable of printing most complex shapes including fan blades. Unfortunately 3D printed parts are not known for their strength. However, a range of new high-strength engineering plastics are now available to 3D printers such as PETG, which is what is used to construct SkyersJet.
When I first had my ideas for this project and researched 3D printing an EDF this large, the general consensus was that it couldn’t be done. However I decided to try anyway.
There are multiple benefits to using a large size. Firstly, SkyersJet has much lower disc loading than other EDFs. Secondly, the gap between the fan and the duct does not have to be as small. Finally, much more power can be put through a larger fan, which enables it to be used for more serious applications such as large fixed-wing or VTOL drones.