Cyclonic scaled prototype

The follow-on to the test project. That rig gathered the needed data for feasibility calculations, they were within tolerances. Next they wanted to understand full scale dynamics and prepare for more extended heat transfer tests (oh, and to verify my ability to execute solo design build at scale). Having it finished in about a month was the directive.

Russel Newman, ex-SpaceX rocket scientist and senior design engineer, acted as advisor/company mode guide (fast, spend the money, be relentless).

Design

The geometry arrived as a spec sheet to be scaled. I took it into Onshape, which I had never used before — Russel supplied the CAD tips, tricks and hacks. (Love you Russ but nothing compared to what I would later get from Dawson and Aggy)

Cyclone cross-section up in CAD at the shop desk

Cyclone geometry in CAD. The shop office.

Process diagrams on the layout table

Walking the test plan on paper before cutting anything.

Fabrication

Sheet steel had to be sorted before being dispatched to different providers, rolled steel to 'Great American Rolling Company' (brilliant name) and the rest to fabricator, Nic.

Flat sheet steel delivery with rolled flange ring

The cyclone, as delivered: flat sheet and a rolled ring.

Rolled barrel with square inlet duct on the welding table

First barrel section, square inlet duct tacked on.

Larger barrel with scroll inlet

The scroll inlet taking shape.

Assembly

A cantilever rack on a steel sheet platform. The whole thing can be moved with a forklift, which mattered more than expected. After this bit of showing off with a forklift I ended up doing quite a bit of forking.

Base rails clamped for welding

Base coming together.

Forklift lifting a frame post

Raising the frame.

Cone hanging in the frame during install

The cone going in.

Assembled cyclone in the rack frame

First full assembly — cone, barrel, and blower in the frame.

Ducting and blower connected The full rig at dusk

Left: ducting on, collection under the cone. Right: the standing rig at dusk.

Process

My favorite gift from Russ -> whiteboard everything, then you get to cross them off: CAD → material order → rolling and bending (outside vendor) → welding → assembly and integration.

Cyclone Dev 1 process flow on the whiteboard

Cyclone Dev 1, the whole plan.

What went wrong

Transport slipped a weekend. Oversized rolling was very hard to source in the first place (far south LA), and then the transport off it was delayed across a weekend. Rented a truck, drove across LA, picked it up myself so work could continue on schedule.
A tube came back heat deformed. The fabricator skipped an assembly step. Fixed it with an over strap. Not noticeable or impactful, phew.
Sent the cutter a .dxf instead of a .step, and they ghosted. Got them the .step and off it went.

What went right

Design for rapid development build worked — one month from design to test.
The cantilever rack on a steel sheet platform gave alacrity and adaptability, and was later repurposed successfully.
The platform's mobility proved crucial as the yard got crowded.

Role

I was responsible for design, procurement, project management, assembly and test. First time in Onshape, and my first run at procurement in the LA Basin.

Russel Newman managed the ClearPath motor for the fan, helped with the ducting, led sensors and data.

Notes

Status: built and ran test. Test platform later repurposed for vertical heavy object storage much needed.
Timeline: CAD late March 2025, standing rig May 1 (Success!)
Outcome: my 'one month' commitment was extended by six weeks...