Use of 3D printing and scanning in the development of a prototype polymer solar collector

In the process of development of a new solar collector the creation of a prototype is a key step in verification of the new design and a basis for further improvements to the design. Due to the novel geometry and materials used in the extrusion process for the prototype collector’s parts and the inability to run the experimental extrusion in many iterations, the parts available for the prototype had significant deviations from the required tolerances and desired geometry. This presented a problem for the assembly of the prototype as the envisioned standardized fittings would not conform to the obtained geometry of the parts. It was therefore necessary to use 3D scanning to obtain the exact size and geometry of every single part with sufficient precision to enable 3D modelling of the necessary fittings required to assemble a prototype collector. Due to the application of this method, a prototype collector could be assembled using 3D printed fittings and tested. This paper provides an overview of the insights and practical considerations that were discovered in this process and suggests improvements in the process which could potentially save time and resources for future projects.