Elastic Rotor – A TPU Flex-Seal Air Engine

Elastic Rotor – TPU Flex-Seal Air Engine

This project explores a rotary air mechanism where flexibility replaces traditional sliding vanes or springs. A circular rotor operates inside an elliptical housing, and the flexible flaps are designed to deform along the changing chamber radius. The elasticity of TPU allows the flaps to act as self-adjusting seals, creating expanding and contracting air pockets during rotation.

Unlike rigid materials, TPU enables controlled bending, surface conformity, and springless sealing — making material flexibility the core functional element of the design.

⚠ Prototype Note:
The printed model shown in the images was produced in PLA for dimensional verification due to material constraints, as TPU filament was not available at the time. The flaps are specifically designed to be printed in TPU (~95A Shore hardness) for proper operation.

This design demonstrates how compliant materials can replace mechanical complexity by turning elasticity into a working component.