Additive Manufacturing as an Enabling Technology for Aerospace - PowerPoint PPT Presentation

Additive Manufacturing as an Enabling Technology for Aerospace Applications Prepared Exclusively for: Aerospace & Defense Forum Ivan J Madera Chief Executive Officer Ivan@Morf3D.com 310-607-0188 821 N. Nash St El Segundo CA 90245

Ab About Morf3D Morf3D is a fully integrated provider of metal additive manufacturing solutions for the aerospace / defense industry. Our team of interdisciplinary experts is disrupting the way aerospace products are engineered, manufactured, and qualified. With a unique and innovative approach we dramatically reduce the product development lifecycle to fully exploit the benefits of metal additive manufacturing. A Value Chain Designed for Repeatability Morf3D, Inc. Confidential, Privileged Information not for Distribution 2

Morf3D’s Ma Mo Market Offering Conceptualization – Advisory Services Post Processing – Finishing Services post- assist clients with the inception of an idea build surface treatment, heat treating, and establish expectations for what is and HIPing, and traditional machining and final isn’t possible with Additive Manufacturing finishing as required Design & Part Optimization – Metallurgy Lab & Inspection – Lab Engineering Services provide specialized Services test coupons, metallurgical expertise in additive manufacturing examination for performance, hardness design, improve design for better testing, and dimensional quality performance / mass reduction assessment - R&D of new materials Metallic 3D Printing – Manufacturing Certification & Data Analysis – Services emergence of initial concept or Documentation Services collection of optimized part from initial prototype quality and build inputs, data analysis and through serialized production – contract documentation for part qualification and manufacturing certification Morf3D, Inc. Confidential, Privileged Information not for Distribution 3

Applica Ap cation Overview - Op Opportunity How ¡additive ¡manufacturing ¡can ¡help ¡companies ¡rethink ¡product ¡design. ¡And ¡the ¡ manufacturing ¡of ¡complex ¡parts ¡-­‑ Opportunity Dr Dramatically reduce product dev evel elopmen ent lif ifecycle le Li Lightweight opportunities – La Lattice, Hollow • • Structures St In Increased performance and functionally integrated • parts pa Im Improved mechanical properties • Ability to manufacture complex geometries Ab Su Supply Chain Efficiency • • Morf3D, Inc. Confidential, Privileged Information not for Distribution 4

Di Disruptive De Design Morf3D, Inc. Confidential, Privileged Information not for Distribution 5

Di Disruptive De Design – To Topology Optimization 41% ¡Weight ¡Reduction, ¡increased ¡stiffness Benefits realized by the use of Additive Manufacturing: - Dramatic weight reduction - Increased stiffness 79% ¡Weight ¡Reduction, ¡increased ¡frequency ¡response - Increased performance - Rapid design iterations - Reduced payload expense - Volumetric efficiency 45% ¡Weight ¡Reduction, ¡increased ¡frequency ¡& ¡stiffness (current payload costs reported by NASA are $20,000/kg) Morf3D, Inc. Confidential, Privileged Information not for Distribution 6

Bi Bionic Design & Optimization (C (Customer: European Space Agency ESA - Se Sentinel 1 Sa Satellite ) Original Design 1.6kg 88.7Hz 163MPa Final Design 0.936kg 91.5Hz Improved Performance and 103MPa Weight Reduction of 41%

Pa Path th To o Qualification on Ne Nesting of Flight Hardware with in-pr process sampl ples Morf3D, Inc. Confidential, Privileged Information not for Distribution 7

Ho Holistic Qualification Process Ho Holistic Process designed for Additive Manufacturing to insure structurally so sound components. s. Morf3D, Inc. Confidential, Privileged Information not for Distribution 9

Me Mechanical & Ma Material Verification Qu Qualification Testing Methods: Tensile Testing, SEM Microstructural Analysis, CT Geometric Analysis, CT Scanning for Internal Defects, Sine Testing De Detail of the Fracture Plane (Horizontal Spe pecimen) Pore in fracture plane is ~30 micron diameter < critical pore size of 150 micron Morf3D, Inc. Confidential, Privileged Information not for Distribution 10

CT Scan CT n and nd Geometric Validation CT Scanning Objectives - Comparison of actual / nominal geometry - Porosity size and relative distribution Results - No visible porosity within the resolution of the CT - No visible defects within the resolution of the CT Maximum deviation = 280 micron (non critical surface) Morf3D, Inc. Confidential, Privileged Information not for Distribution 11

EN ENVISION – Im Imagine & Discover Wh What is possible with Additive Manufacturing? Where are the opportunities and challenges for a client? New markets; new – customers; keeping current customers What complex design problems can a client solve for its clients? New – products; new designs for current products; new processes Which areas in the supply chain does a client want to disrupt? – What do you want to transform? How you design, how you do business, – how you serve your customers? Can we improve our current level of performance through additive – manufacturing? What materials do you want to print? Many applications exist. – Which end-of-life or new parts could be supported with additive – manufacturing? Morf3D, Inc. Confidential, Privileged Information not for Distribution

EVOLVE EV E – Pl Plan & Design Explore the options that create the foundation for the Additive Ex Manufac Man acturing tran ansformat ation: What percentage of parts could potentially be designed and produced – through AM? Identify opportunities to reduce product weight using AM? – Explore ways to disrupt the supply chain and improve client services by – reducing NPD time by months Gather and define a your requirements, analysis of which AM technologies – may be right for operations What changes will you need to make to our supply chain? – What added engineering design capabilities do we need in house or with a – partner to design, manufacture and support AM? Plan for Center of Excellence or Innovation Lab strategy to drive investment – decisions Identify a candidate use case – Develop business case – Morf3D, Inc. Confidential, Privileged Information not for Distribution 13 13

EMER EM ERGE E – Pr Proto toty type & Operati tions Realize the possibility of what is next. EM Re EMER ERGE to to make it t real th through prototypi pr ping and d ope perationalization: In order to have an impact, commit to implementing the changes identified – during the EVOLVE Confirm approach and timing of pilot process if applicable – Develop prioritized plan for improvement – Determine technology requirements and plan – Define technology partners and operations – Define additive manufacturing capabilities and go-to-market strategies – Clearly define structures to support the People, Processes, Change, and – Technologies centered on additive manufacturing Morf3D, Inc. Confidential, Privileged Information not for Distribution 14

In Innovation Center – El El Segundo, CA. Unfair Advantage Digital Rende Explosion ¡proof ¡enclosure ¡– 2 ¡EOS ¡M290 Enabling ¡the ¡Future ¡– Summer ¡Interns Engineering ¡and ¡Collaboration ¡Space ¡ ring - Strategically located in El Segundo, CA (Named: The Aerospace Capital of the World) - 6,700 S.F. of Collaboration / Mfg. - Latest AM-Metal DMLS Technology - Video Walls for hands on design instruction and part optimization - Metallurgy Lab & Testing Equipment Digital Rendering 15 Morf3D, Inc. Confidential, Privileged Information not for Distribution

Additive Smarts. 16