Materialise : How 3D Printing Made a Fullsize Model Airplane from World War II

"We designed the system in such a way that there are at least two tubes running through every contour, ensuring that the contours will stay in place and will not rotate around the tubes," explains Wouter Maleux, from Materialise's Design & Engineering services. "Besides using printed connectors, 3D printing was also a key part of the manufacturing process itself. We designed drill jigs using 3D-printed parts and carbon tubes to create a smooth assembly process that would give clean, consistent results."

The finished plane is reminiscent of balsa wood model airplanes found in toy stores. But rather than a 1:72 scale model that might hang from a child's bedroom ceiling, this model is the same size as the plane it represents.

The completed model will be displayed outdoors in an open field. Therefore, like a real airplane, it needs to be able to withstand different weather conditions, all while staying firmly on the ground! The creators wanted to ensure that it can also survive the wear and tear of visitors who can't resist touching it while taking selfies. The Materialise Design & Engineering team undertook an FEA analysis with different load scenarios and wind speeds of up to 100km/hour and are confident that it will look just as good in the years to come as on the day it is unveiled.

The model was pre-assembled by Materialise Manufacturing in Leuven before making the 20km journey to its permanent home - on land rather than by air.