Trim Tab 3D Print Musings

[fl-mike]

I had some time to kill, so thought I might model up the trim tab in CAD with the thought of molding one out of carbon fiber.
Then thought "why not 3D print it?" Some details like the hinge flange would need to be figured out, but here's a proof of concept print (some angles and dimensions need adjustment).
Discuss!

 

[plehrke]

I would be very leery putting a 3D printed part of a control surface on my airplane. Not worth the risk and probably minimal advantages over sheet metal. at minimum there needs to be some stress analysis and proof testing especially of the hinge attachment.

 

[F18Sailor]

I too would be leery of this. Molded carbon has ~20x the strength of 3D printed ASA. Aluminum is ~5x stronger. Now, you could wrap the 3D printed part in carbon and possibly obtain a functional part. I would still opt for a MJF/SLS nylon base part. Also, the hinge seal as printed won’t hold up.

That being said, I have designed and flown airplanes with 3D printed hinge bushings encapsulated in carbon (and carbon rods used as the hinge). Everything worked as designed, however, our Vne was the same as an RV’s approach speed. The control surface itself was also a fully engineered molded carbon surface.

 

[DanH]

Is it lighter, or more specifically, does it have equal or less moment of inertia?