Posted on 12/19/2025 5:45:46 PM PST by xxqqzz
A Cozy Mark IV suffered a total engine failure and crash in the UK - yet the pilot survived. The cause? A 3D-printed engine induction part that failed mid-flight. In this video, we break down the official accident report, recreate the flight using ADS-B data, and explain exactly how and why this failure happened.
This isn’t just a canard story. It’s a critical lesson for all experimental and homebuilt aircraft owners, especially anyone using or considering 3D-printed parts in the engine compartment. We’ll cover the pilot’s decisions, glide profile, energy management, material science failures, and—most importantly - what you can do to make sure this never happens to you.
(Excerpt) Read more at youtube.com ...
Avoid 3D printed nuclear plants as well.
3D printing is a nice technology, when used properly.
In Engineering, I have seen it used poorly and abused extensively.
Takes the thought out of design, sort of like AI does to many things.
Both have valid applications, when used judiciously.
A Buddy had a LongEZ in SanDiego...
I liked the Luscombes and Cubs !
.
Good Video!
There’s a reason plane parts are expensive. Extensive testing is expensive.
Not as Cozy as he thought.
A friend of mine built a varieze. I donated a bag of shot for the fwd ballast. I got to ride in it once.
Banging Rivets,Laying Fabric,
Engine Leakdowns and occasional
Shots of Jack Daniel’s.
Twenty Years and No Rough Landings
and I’d say it was a Good Bunch.
The Ferrari of Home Builts...
Lucky!
Wow, the author posits the maker of the air duct LIED about the material. Instead of carbon fiber, he made it from a polymer. Transition temp was 105C for carbon fiber and only 55C for the polymer. The engine compartment got hot at low power due to reduced cooling flow, the polymer air duct collapsed under engine vacuum and cut off air flow to the engine!
SpaceX 3D prints their rocket engines. It’s not all flimsy.
Many different methods. Not sure what parts you are referring to but there are huge differences between powdered metal laser sintered “3d printed parts” and extruded plastic 3d printed parts.
Lowest bidder gets the contract.
yep, with Iconel, a super strong, super heat-resistant form of iron ...
The processes in the article made a plastic part that was not up to temperature requirements. 3D printing a rocket engine is a process that welds metal to form a part.
When lives are at stake, and safety is paramount, a good builder will never
use less the 4D parts. Even better is the margin provided by a 5D printer.
Take it to the bank.
Styrofoam is not structural.
Was this 0360 fuel injected or normally aspirated? If normally aspirated pulling carb heat might have saved him.
Actually it is when covered with hard fiberglass with a main spar running down the middle of the wing. Without the foam the wing would collapse.
Used PLA instead of PA6?
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