Overview:

If you've experienced a Fluxspace STEM Day or engaged with our social media channels, you may have seen our DIY wind tunnel in action. Recently, we built another one, and today, we're excited to take you through the process step by step.
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Materials:

• Cardboard: for the tunnel walls and base
• A PET-G plastic sheet: for the observation window and cylinder tunnel (can use vinyl sheeting instead)
• A box fan: to generate airflow
• Two large 18” wooden embroidery quilting hoops: for support

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Step 1: Planning and Measuring

Before we could start constructing the wind tunnel, we needed to carefully plan out our design and take precise measurements for each component. To begin, we measured and

marked out the dimensions of the cardboard panels that would form the tunnel’s structure, as well as the size needed to accommodate the embroidery hoops, ensuring they fit snugly inside for reinforcement. Additionally, we calculated the appropriate size for the PET-G plastic cylinder, allowing for an unobstructed view while ensuring it remained securely attached.

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Step 2: Cutting the Materials

With our finalized design, we began cutting out each piece using the materials listed. The two primary cutting tools we used were:

• Chompsaw: which allowed us to make clean, straight cuts for the larger cardboard sections.
• Makedo Tools: a set of tools designed for building with cardboard, ideal for more detailed trimming and adjustments.

The PET-G plastic sheet was carefully trimmed to the correct size, ensuring that it would fit snugly within the cardboard.

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Step 3: Assembling the Wind Tunnel

Once all of our materials were cut, it was time to start assembling the wind tunnel. To secure the cardboard pieces together, we used Makedo tools. These connectors allowed us to fasten the panels tightly while still providing some flexibility for adjustments as needed.

We started by assembling the main body, carefully aligning the cardboard panels, and securing them along the edges with Makedo screws. The wooden embroidery hoops were

inserted at either end of the PET-G cylinder to provide additional support and maintain the cylindrical shape. Once the tunnel frame was stable, we ensured it was firmly in place and free from gaps.

Finally, we positioned the box fan at the entrance of the wind tunnel, securing it so that it would blow air consistently through the structure.

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Step 4: Final Inspection

Once everything was assembled, we checked for any weak points or misalignments. After confirming the structural integrity, our wind tunnel was ready for use!

Building this DIY wind tunnel was a process that combined engineering, problem-solving, and creativity. Whether you're testing aerodynamics, demonstrating airflow principles, or just looking for a fun STEM project, a homemade wind tunnel is a fantastic way to explore these concepts.

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