Additive Manufactured Functional Prime Mover

The development cycle of additive manufacturing technology, also known as 3D printing, has reached a stage of industry acceptance. Established multinational 2d printing companies, for example Hewlett Packard, who were not formally associated with additive manufacture (AM) are now actively progressing their own technologies. Associated with this, thousands of application frontiers are being established and whilst the technology opens many paths to the manufacture of parts not previously possible there are also restrictions on what can be made using AM when using traditional design practices. For example an engine cylinder bore can't currently be manufactured using AM that does not require post machining. Select engine parts, such as gas turbine blades, are being made using AM and the number of parts used in prime movers will increase as the technology develops. With AM proliferation, changes to the practices of prime mover designers and maintenance personnel will be required. This work explores ways engine design can be modified to suit AM. Making a fully functioning Stirling engine made solely by AM was a logical starting point as they use an external heat source and don't require precision machined parts like valves and injectors. This work presents the design choices used for a making a fully functioning engine using only AM parts that did not require post machining.