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Research institutes and companies are currently working on 3D numerical icing tools for the prediction of ice shapes on an international level. Due to the highly complex flow situation, the prediction of ice shapes on three-dimensional surfaces represents a challenge. An essential component for the development and subsequent validation of 3D ice accretion codes are detailed experimental data from ice shapes accreted on relevant geometries, like wings of a passenger aircraft for example. As part of the Republic of Austria funded research project JOICE, a mockup of a wingtip, based on the National Aeronautics and Space Administration common research model CRM65 was designed and manufactured. For further detailed investigation of electro-thermal de-icing systems, various heaters and thermocouples were included.

This work introduces an approach allowing the detailed replication of ice shapes generated in icing wind tunnels, with a special focus on complex and strongly varying ice structures, e.g., ice feathers or residual ice stemming from incomplete removal of accreted ice by ice protection systems. 3D-scans are used as an input for the manufacturing process of the ice shape replica. The manufacturing approach itself is based on additive techniques using semi-flexible materials. In contrast to existing replication techniques, this approach allows also clean areas between ice-covered surface locations. In the present paper, a quality assessment based on the comparison of the lift coefficients of real and corresponding artificial ice shapes is presented.