Aeroacoustic and aerodynamic evaluation of SLA-printed cross-flow fans: desktop vs. industrial-grade fabrication

Purpose The application of stereolithography (SLA) for functional turbomachinery components remains a developing area of interest, particularly regarding the performance impact of fabrication scale. This study aims to evaluate the aerodynamic and aeroacoustic performance of cross-flow fan (CFF) rotors fabricated using desktop and industrial-grade SLA machines, highlighting how geometric fidelity and mechanical behavior influence fan efficiency and noise. Design/methodology/approach CFF rotors were 3D printed using both desktop and industrial SLA printers. Mechanical properties were evaluated based on layer orientation and postcuring temperature. Aerodynamic performance was assessed experimentally via static efficiency and pressure coefficient, while aeroacoustic behavior was characterized using sound pressure level (SPL) measurements across various flow coefficients and rotational speeds. Geometry distortions were linked to observed performance discrepancies using theoretical modeling grounded in Euler’s equation and blade angle analysis. Findings The results show that postcuring at 80°C significantly improved tensile strength, with up to 110% gain at 0° orientation. The desktop-printed rotor exhibited a 10–15% reduction in peak aerodynamic efficiency and a ∼1 dB increase in SPL, primarily due to blade deformation and altered inlet/outlet angles. Theoretical analysis confirmed the sensitivity of CFF performance to blade alignment, validating the observed effects. Despite minor drawbacks, desktop SLA was found viable for rapid prototyping in fan design. Originality/value This work offers a novel experimental–theoretical framework for evaluating desktop SLA in aerodynamic and acoustic applications. It provides insights into the relationship between manufacturing fidelity, mechanical properties and functional performance of CFFs. These findings can inform the design and validation of 3D-printed turbomachinery components using accessible laboratory-scale equipment.