Abstract
<title>Abstract</title> <p>Boundary Layer Ingestion (BLI) propulsion offers significant efficiency gains but poses challenges in experimental validation due to complex airframe-propulsion interactions and inlet distortion. This work presents the design and optimization of a down-scaled wind tunnel model (WTM) based on a novel electrically powered simulator (EPS) for an aft-mounted BLI configuration. The EPS replicates full-scale transonic aerodynamic conditions via Mach-similar scaling and enables precise control of flow parameters, avoiding the thermal and mass flow limitations of turbine-powered simulators. The EPS stator section is designed to host all required media connections while fulfilling the aerodynamic requirements at the same time. A re-designed process using inverse airfoil design and 3D RANS simulations, improved pressure recovery and reduces end-wall losses, increasing isentropic efficiency by 4\% compared to the baseline. The optimized design achieves a target efficiency of 80\% at 50 kW shaft power while maintaining all aerodynamic flow conditions of the stage, while minimizing swirl downstream of the stator vanes. An exergy-based analysis quantifies total losses, enabling a physically consistent assessment of performance degradation. The resulting WTM provides a reliable platform for validating numerical predictions and advancing the development of integrated BLI propulsion systems.</p>