Manufacturing vortex generators with resin 3D printing and CO₂ laser cutting
Vortex generators are small aerodynamic parts with a real impact on airflow behaviour over a wing. In this project we manufactured a series of resin vortex generators for a light aircraft, following a complete workshop process: from manufacturing through to preparation for final installation.
Introduction
Vortex generators are small aerodynamic parts with a real impact on airflow behaviour over a wing. In this project we manufactured a series of resin vortex generators for a light aircraft, following a complete workshop process: from manufacturing through to preparation for final installation.
Why print vortex generators in resin
For this type of part, geometric precision and repeatability are key. Resin 3D printing makes it possible to reproduce small, well-defined profiles with much higher surface quality than other additive methods.
Instead of machining each part or making moulds, direct printing was chosen, which makes it possible to:
- Repeat exactly the same geometry on every unit.
- Control angles and edges that influence vortex generation.
- Reduce time and costs for small or medium batches.
Post-processing: curing, priming and painting
Once printed, the parts undergo a complete curing process to ensure dimensional stability and strength. A specific primer is then applied to improve paint adhesion and protect the resin from external agents.
The final finish is applied by painting, not only for appearance but also to:
- Make the surface uniform.
- Improve resistance to UV rays.
- Facilitate visual inspections once installed.
CO₂ laser cutting for precise placement
Correct placement of the vortex generators is as important as their shape. For this purpose, a template and auxiliary elements were designed and manufactured using CO₂ laser cutting, ensuring consistent and repeatable alignment on the wing.
Using the laser makes it possible to work with tight tolerances without damaging surfaces and enables clean, controlled installation.
Fixing system with 3M tape
Each generator includes high-quality 3M double-sided tape selected for technical applications. This system provides firm attachment without drilling, keeping the wing surface intact.
Before final installation, the surface is prepared to ensure correct and durable adhesion.
When it is not advisable to improvise with this type of part
Vortex generators are not merely decorative elements. Incorrect geometry, an unsuitable material or imprecise placement can cancel their effect or even create unwanted effects.
That is why this type of work should be approached technically, combining design, manufacturing and installation in a coherent way.
If you need custom technical parts manufactured by 3D printing or laser cutting, we can help you define the right process from the outset.