This is the BSI-2 thruster. Like its predecessor, it relies on tens of thousands of volts to create thrust using no moving parts. Unlike its predecessor, it's half the size, moves twice as much air, and is much more durable.
You see, back in 2018, MIT built the world's first ionic thruster plane. So in response to their work, I recently designed what I called a next gen ionic thruster. The months of work I put into it led to a decent first prototype and a measurable amount of thrust. But it was actually quite basic. At the end of my video on the thruster, I acknowledged the design had room for improvement, but it does have some inefficiencies, I'm thinking of three in particular. Well, it had a lot of room for improvement, actually.
And after a friend of mine over in Portugal built his own ionic thruster and crowned himself the Velocity King. 5 meters per second, almost six. It was time for me to step up to the plate and create the BSI mark 2. Dude, that's a huge improvement! So the video on the first BSI thruster was really well received. And since I acknowledged in the video that my design had room for improvement, it was basically an open call for you to critique my work. And I received a lot of great feedback, and a lot of feedback that would have made the design terrible.
在我在葡萄牙的朋友制造自己的离子推进器并自封为“速度之王”后,他的速度每秒达到5米,几乎是6米,我也该站出来制造BSI Mark 2了。哇,这可是一个巨大的改进!第一部BSI推进器的视频反响不错。由于我在视频中承认我的设计还有改进的空间,这基本上是一个公开的号召,让你批评我的工作。我收到了很多很好的反馈意见,也有很多反馈意见可能会让设计变得可怕。
Overall I wanted to design a thruster which was modular and capable of eventually propelling a fixed-wing airplane. It was a huge engineering challenge, so I took my time and worked on other projects in the meantime, like my plasma-filled river table. But then my friend Joel reached out, curious about the thruster. He wanted to build his own, so we chatted for a bit about operational theory, and with a smug grin on my face, I thought, well I'm sure his attempt will be cute. Fast forward a month, and it was more than cute. His thruster achieved Velocity's far greater than mine did, and it was much more compact. 5 meters per second, almost six. Almost six meters per second. I was proud of my friend. However, it called into question who I ultimately was. I mean, what was I? Was I plasma channel or plasma enough channel?
Eventually the defeat got to me. It was at this time I realized the universe needed the BSI Mark II. Let's go. The new thruster would feature several improvements. First, since I've learned a 3D print, many of the structures and supports could be designed lighter and more compact. Additionally, the round electrodes on my first thruster introduced turbulence, and the brass added lots of weight. So all the electrodes need to be designed with an aerodynamic shape in mind, and reduced weight. Maybe I'd experiment with different configurations for the electrodes and see how that affects output.
最终,失败打败了我。就在这时,我意识到宇宙需要BSI Mark II。我们走吧。新的推进器将具备几个改进:首先,由于我学会了3D打印,许多结构和支架可以设计得更轻且更紧凑。此外,我的第一架推进器上的圆形电极引入了湍流,并且黄铜增加了很多重量。因此,所有电极都需要考虑其气动形状并减轻重量。也许我可以尝试不同的电极排列方式,看看它对输出的影响。
And the last major improvement was a little bit of an engineering task, but you know what? I was up for the challenge. The open frame of the last thruster was great for testing terrible for a fish and air flow. So I wanted housing which provides auxiliary airflow from the sides while containing and focusing the air already moving within the thruster. I had my work cut out for me.
I figured the best place to start would be to optimize a single section of the thruster first, right? And then move on from there. So I started with some 3D design and acrylic work. Alright, here's the assembled first stage of the thruster and I want to optimize this design before moving on to other stages.
But there's a couple of key features. First of all, the inlet utilizes a semi-venturie shape which should help a lot with airflow and drastically reduce any currents. And second, there's an adjustable inlet for air between the positive and the negative electrodes. Now this allows air to be sucked in from the sides during operation because of the low pressure inside the main body.
For all the tests, I'm using this power source. It pulses 15 volts into a flyback transformer which feeds a voltage multiplier about 8,000 volts producing 50,000. Let's test it. I started the tests with a 25 millimeter electrode spacing. I've got everything wired up and I busted out the same wind meter I used last time. Let's just plug this in and see. One point one point four one point five.
Next, I close the distance down to 16 millimeter spacing. Alright, let's give this another try. Oh man, 2.2 meters a second. That's unreal. 2.3, 2.4. Oh, that's unreal. I ended up running the test two more times because I just I really couldn't believe those numbers. And in reality, the average speed for a single stage of the thruster was close to 2.1 meters a second, which still totally blew me out of the water.
Now, even though I was pleased with the results I suspected, it could improve if the electrodes are spaced even closer. So I went back to the 3D design board and removed about 9 millimeters of length from the Venturi shroud. After eight hours of printing and several cups of coffee later, the new shroud was brought into reality. A quick rewiring of the positive electrode and reassembling of the first stage and it was good to go. I am curious what effect this is going to have. One way to find out.
Oh wow, 2.2, 2.3. That modification, man, that made a huge difference. This is going to be an epic thruster. Like before, I ran a triplicate test and found that speed is averaged 2.3 meters a second. That was a 10% increase. At this point, I really wanted to visualize the airflow better. You know what it looked like. So I used a couple of methods that have worked for me on the first thruster.
Alright, so I want to know how does a candle stand up to this? Not even a chance. But to really see the airflow, I headed to a seafood department and grabbed some dry ice. It's a wonderful source of fog, especially when placed in hot water. The blacker acrylic is just for better visibility. Flipping the switch, it was clear the Venturi inlet was doing its job. Beautiful.
A really common suggestion I received for improving the first BSI thruster was to take the electrodes and place them perpendicular to each other. Curious to see what would happen, I gave that a try. Is this a good change? Let's find out, shall we? Oh, it's about the same. Actually, that's a little bit worse. That's kind of surprising. The average speed this produced was 2 meters a second, which honestly was kind of surprising because I assumed the cross grid structure would lead to more predictable and organized spots where the ionic winds being produced, right? Everywhere the wire is crossing. That wasn't the case. This told me that parallel is king.
So far, all tests used a positive wire spaced between the grounds. Printing off another version, I was curious what effect placing the wire directly in front of them had. So I ran another test. It's about the same as before. 1.92 meters a second. Yeah, it's pretty steady at about 2 a second. It sounds terrifying though. Further tests showed that having electrodes perfectly lined up led to an average speed, again, of only 2 meters a second. So this told me that having the offset electrodes was actually the most efficient configuration.
Consider this. The old thruster put out 2.3 meters per second and it had three stages. This is just a single stage of the new thruster and it already puts out 90% of the velocity of the first version. That's a really good sign. And considering it weighs just over 120 grams, it's proportionately lighter as well. At this point, I had successfully created the world's crappiest and least OSHA compliant hairdryer. If I achieved upwards of 2.3 meters per second, with just a single stage, I sure as hell was curious what velocity three stages would bring.
After a couple days of 3D printing, I was able to assemble the three stages together and address that question. Fully assembled, woo, what a beaut. You've got three identical sections of identical spacing between the sections and spacing between positive and negative electrode. You have an inlet for air right here and two auxiliary inlets on the side. I think this design is going to perform super well and only one way to find out. This is going to be sick. Oh yeah, 2.9, 2.0, can we get three? Three! Three meters a second. That's so cool.
While that was an improvement, I essentially tripled the weight of a single stage, while only adding 30% more velocity. Hardly a win. So, I called up my friend Alex, who works at a rocket company in Los Angeles. We bounced ideas back on fourth on what tests we could perform to discover limitations of my design. Have you been playing with grid spacing? Eventually we settled on one test that would be very telling.
Here's the setup of God. Two separate sources of airflow, a separately powered PC fan in the front, followed by a single stage of the thruster. Now the fan puts out about 2 meters per second and the thruster also around 2 meters a second. So, what I want to know is when they combine, is it linear? Will it create 4 meters a second downstream? So, the thruster is on at about 2.1 meters a second. Now to give it a boost from the fan. 0.1 meters, 0.2 meters a second boost, that makes no sense.
That test was pretty useful because it revealed a design flaw, which is that any air coming in at 2 meters a second or faster doesn't quite have enough time to interact with the next set of electrodes and be influenced to go faster. So, essentially the second and third stages don't really help very much.
To remedy this, I started by digging into NASA's designs for ionic thrusters. I also hit up my subscribers to see if any of them had experience with this. I received a lot of great offers and Charlie's response stood out to me. So, I hopped on a video call with him where he suggested using thinner wire and elongated grounds, which made physical sense. This meant yet another reprinting and further weighting. And by weighting, I mean 15 hours.
While that printed, I had plenty of time to reflect on this video sponsor. So, this entire project was originally inspired by when I read that MIT had created an ionic thruster plane. And it was super cool. It was in the news. Honestly, it was all over the news. And that's why sponsors like Morning Brew are so important.
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All right, on to some thrust. Originally, the positive electrode had 32 gauge wire, easy to see. I changed that to 36 gauge, which is much thinner. And while the old ground used typical round tubing, the new ground electrode steps it up a notch with aerodynamic tubing. I also shortened the spacing between the stages by about 10 millimeters, which brought the thrusters new length to just over seven and a half inches or 19 centimeters. Total weight now equaled 450 grams, which is 10 percent lighter than the first BSI thruster or a full can of my favorite drinkable nitroglycerin.
For testing, this thruster needed a proper stand, which meant one thing. Ah, nothing quite pops like nuclear green acrylic. Let's test these changes. So the lowest power level, about 30 watts, brings us 1.6, 1.7 meters a second. 50 watts brings us 2.4, 2.6. Okay, and this is full power at about 90 watts. 4, 3.8. Dude, that's a huge improvement.
Four meters per second obviously excited me, so I wanted to see the airflow on the final thruster. And the results blew me away. Oh, that's just biblical. You can see the inlet doing its job with smooth airflow over its edges and a tremendous amount of air movement. But what about the auxiliary inlets on the side? Were they pulling in additional air? You can see it right here, they are working beautifully.
Eagerly wanting to see the airflow on the output, I leaned on an old friend, the pyro inside of me. Oh, God. Woo! Oh my God. How's that for airflow? Oh, woo! The airflow on this is just insane. It has a 12 centimeter diameter and it's pushing air at about 4 meters a second, right? Let's compare this to the first BSI thruster and see how it measures up. Mark 1 measured 38 centimeters, 495 grams, produced 2.3 meters per second, and was super fragile. Mark 2 measures 19 centimeters is 10 percent lighter at 450 grams, produces 4 meters a second, and is structurally solid. I think it's pretty clear this is a huge improvement.
For an explanation of the science behind the thruster, my first video details the physics behind ionic thrust. Ultimately, the work put into this thruster taught me a ton about airflow, and it brings me one step closer to an ionic thrust airplane of my own design. Ultimately, that is the goal of the thruster. Good progress, but a lot of work to be done.