Miniature Design · Optimization Engineering

3D Printed Wind Mill

Comprehensive design, analysis, manufacturing, and testing of a miniature 3D-printed windmill optimized for maximum power generation, structural stiffness, and minimal weight—achieving top 5 performance among 140 UC Berkeley students.

Design Objectives & Methodology

This freshman-year engineering project challenged students to design and manufacture a miniature windmill with multiple competing objectives that required careful optimization and engineering trade-offs.

Power Maximization

Optimize blade geometry and configuration for maximum energy conversion efficiency

Structural Optimization

Maximize stiffness while minimizing weight through topology optimization

Creative Design

Innovative approaches to traditional windmill architecture and functionality

Manufacturing

Design for 3D printing constraints and assembly requirements

Design & Engineering Process

CAD Modeling

Complete SOLIDWORKS assembly including base, blades, and motor attachment

FEA Analysis

Structural analysis to optimize stiffness-to-weight ratio and ensure integrity

Blade Optimization

Three-blade configuration for enhanced flow speeds and rotational force

Topology Optimization

Cylinder-based structure optimized to reduce weight while maintaining stiffness

Testing & Performance Analysis

Measurement Methodology

Connected a precision power meter to the motor for comprehensive electrical measurements, capturing power output, current draw, and voltage generation under various loading conditions.

Optimization Process: Conducted methodical search for optimal loading conditions on the potentiometer, manipulating circuit resistance to achieve peak performance. Extended evaluation to structural testing through top plate loading and deflection measurements.

Circuit Integration

Designed and implemented electrical measurement system with variable loading to characterize power curve and identify maximum power point for the wind turbine generator.

Performance Results

680.2

Milliwatts Generated

12.8

Stiffness (N/mm)

14.2%

Efficiency Rate

Competitive Performance: Achieved efficiency rate of 14.2%, notably competitive with conventional full-scale windmills that typically operate at 30% efficiency. This represents excellent performance for a miniaturized system with inherent scaling challenges.

Academic Recognition: Performance metrics positioned this project in the top 5 among a cohort of 50 UC Berkeley students, following rigorous testing that assessed power output, weight considerations, and structural load-to-deflection ratio.

Technical Insights & Engineering Learnings

Multi-Objective Optimization

Balanced competing requirements of power generation, structural integrity, and weight constraints through systematic design iteration and FEA validation.

Topology Optimization

Applied advanced CAD techniques to create lightweight structures with optimal stiffness-to-weight ratios, crucial for miniaturized mechanical systems.

Aerodynamic Design

Three-blade configuration optimization demonstrated the importance of blade geometry and spacing for maximizing rotational force and flow capture efficiency.

Electromechanical Integration

Power measurement system design and circuit optimization provided hands-on experience with generator loading and maximum power point tracking.

Manufacturing Constraints

3D printing limitations influenced design decisions, teaching valuable lessons about design for additive manufacturing and material properties.

Testing Methodology

Comprehensive testing protocol combining electrical measurements with structural analysis demonstrated importance of holistic performance evaluation.

Project Impact & Future Applications

This project served as a foundational experience in mechanical design optimization, introducing critical concepts that have influenced subsequent engineering work. The challenge of balancing multiple competing objectives—power, stiffness, weight, and manufacturability—provided practical experience in real-world engineering trade-offs.

Design Methodology: The systematic approach combining CAD modeling, FEA analysis, and experimental validation established a design methodology that has proven valuable in subsequent projects. The integration of simulation with physical testing demonstrated the importance of validation in the engineering process.

Optimization Thinking: Working within the constraints of miniaturization while maximizing performance taught valuable lessons about scaling effects and the importance of understanding fundamental physical limitations in engineering design.

Ranking Achievement: Placing in the top 5 among 140 students validated both the technical approach and the importance of rigorous testing methodology. This recognition highlighted the value of thorough analysis and systematic optimization in competitive engineering environments.