Additive Manufacturing Fundamental Concepts DAU Lunch & Learn 02.07.2018 Tuke Klemmt, MLS, Director Rashid Faraby, MLS Dave Floyd, Moderator Katherine Multop, MLS DAU FLD-LOG DAU Knowledge Repository https://identity.dau.mil/EmpowerIDWebIdPForms/Login/Krsite Presentation Title
PRESENTATION AGENDA Tuke Klemmt Introduction Research dive into the literature – takeaways Katie Multop How services are implementing this technology Industry perspectives Prepare a 3D model for printing Rashid Faraby Learn how to operate a 3D printer Lessons learned Wrap-up Tuke Klemmt Additional questions 2
Benefits • Reverse engineer (scan) and duplicate obsolete parts • More exact fit/ duplication than traditional manufacturing • Good for low-volume, high-complexity/ high cost parts • Capable of creating more complex and freeform designs in one piece • Customizable Tooling jigs • Rapid prototyping • Less material waste, lower cost • Less downtime for warfighters through rapidly manufacturing replacement parts on site Wang, X. Y. (2016). Using additive manufacturing to mitigate the risks of limited key ship components of the Zumwalt-class destroyer . NPS. Gaska, M. & Clement, T. (November-December 2016). Additive Manufacturing as a Sustainment Enabler. Defense AT&L . 3
Benefit Complex Shapes NOTE: The original part was manufactured in three sections and welded together while the 3D printed part was manufactured as one piece. By eliminating the welded seams, the part is stronger because it now has two less points of failure.” “The original part would have taken six days to manufacture but the 3D printed part can be manufactured in just one day.” Gager, K. R. (April 1, 2017). Just Do It Yourself: Implementing 3D Printing in a Deployed Environment . Air University. 4
Issues/Concerns • Property and intellectual rights • Contractual issues • Cybersecurity • Lack of standardized production processes • Lack of quality assurance methods or standards • Significant material variability • Possibility of reduced material performance Goh, G., Agarwala, S., Goh, G., Dikshit, V., Sing, S., & Yeong, W. (2017). Additive manufacturing in unmanned aerial vehicles (UAVs): Challenges and potential. Aerospace Science & Technology , 63 Langlais, R. Jr., Avdellas, N., Finfrock, C., Salley, R., & Newcomb, M. (November-December 2016). Separating hype from reality. Defense AT&L. 5
Concern Weak Bonding and Residual Stress Validating Isotropy in SLA 3D Printing. (October 12, 2016) Residual stress is a result of heating and cooling, expansion and contraction, that occurs during the metal 3D printing The porosity of a material and poor bonding between layers may process. When residual stress exceeds the tensile strength of weaken the overall structure of an additively manufactured the printing material or substrate, defects, such as cracking in component. This makes it unsuitable for the replacement parts that the part or warpage of the substrate, can occur. Molitch-Hou, USAF wish to eventually fabricate in the field. Haria, R. (October M. (July 10, 2017). 7 Issues to Look Out for in Metal 3D 24, 2017). U.S. Air Force summons Synchrotron to investigate 3D Printing. Engineering.com . printed layering. 3D Printing Industry.com. 6
Army Grenade Launcher (RAMBO) 1 https://youtu.be/VBXbtgwh89o • B-hut 2 https://youtu.be/LjBS6b7ZeF8 • MRAP valve stem covers 3 https://youtu.be/hzGGNyMjvgg • 1 Burns, S. K. & Zunino, J. (April-June 2017). RAMBO’s premiere. Army AT&L Magazine . 2 Jazdyk, M. (August 22, 2017). 3-D printing a building . US Army Corps of Engineers. 3 Asclipiadis, A. (Master Sgt.). (July 9 2014). Rapid Equipping Force uses 3-D printing on the frontline . Army.mil. 7
Army Program Solutions to Unanticipated Problems “The solution began as a simple cap made using the 3-D printer and, by the fifth and final version, it morphed into a metal cover that could easily attach to existing bolts on the wheels… In concurrent discussions with Project Manager MRAP, REF learned that a wheel redesign effort was already under way; however, it would take more than a year to outfit all vehicles in theater. PM MRAP recommended REF continue to bridge the immediate need until the long-term solution could be implemented. From beginning to end, the entire design, manufacture and delivery took less than five weeks.” Asclipiadis, A. (Master Sgt.). (July 9 2014). Rapid Equipping Force uses 3-D printing on the frontline . Army.mil. 8
Navy Submersible hull 1 – Disruptive Technology Lab and Oak Ridge National Laboratory • https://youtu.be/_GlxVjAHofk MV-22B Osprey titanium link and fitting assembly for engine nacelle 2 • https://youtu.be/l7yrwGt6iFw Trident II D5 Missile 3 – one-inch wide aluminum alloy connector backshell component • 1 Jackson, T. (July 20, 2017). Navy Partnership Goes to New Depths with First 3D-Printed Submersible . Energy.gov. 2 Freedberg, S. J. (August 3, 2016). First Osprey Flight With Critical 3D Printed Part. Breaking Defense. 3 Grunewald, S. J. (March 22, 2016). US Navy’s Trident II D5 Missile Successfully Launches with 3D Printed Component from Lockheed Martin . 3Dprint.com. 9
Navy Submersible “Chief of Naval Research Rear Adm. David Hahn listens as Garry Shields (left), head of Naval Surface Warfare Center, Carderock Division™s Disruptive Technology Laboratory, describes the Optionally Manned Technology Demonstrator (OMTD) Big Area Additive Manufacturing (BAAM) test article, which is a 30-foot- long, proof-of-concept hull print modeled after a SEAL delivery vehicle.” Diaz, D. Q. (July 20, 2017). NAVSEA Recognizes Carderock Innovators, Partners for Unprecedented Naval Asset . Navy.mil. 10
Marines Drones – Nibbler 1 https://youtu.be/UUmhCXXJEpk • • Chain-drive sprocket for 25mm Bushmaster chain-drive ammunition loader – It has “similar tensile strength (5,000-7,000 psi) and comparable flexural modulus (270,000-380,000 psi) relative to the” traditionally manufactured part. 2 3d printed sprocket, on the right, made of Acrylonitrile Butadiene Styrene (ABS) plastic 1 Eckstein, M. (September 27, 2017). Marines’ 3D-Printed ‘Nibbler’ Drone Creating Lessons Learned on Logistics, Counter-UAS . USNI. 2 Hrynewych, R. (Capt.). (n.d.). Marines conduct live-fire testing with a 3D printed part . SecNav.navy.mil. 11
Marines Nibbler Quadcopters capable of carrying cameras or other intelligence payloads 20-25 minutes flight time / $2,000 a piece / created by Ripper Lab (7 th Marine Regiment) 12
Air Force F-35 prototyping of fuselage and wing skins by Lockheed Martin 1 • F-22 cockpit floor structural mock-up 1 • F-35 Wind Tunnel Model F-22 Cockpit Floor Cost savings: $65K Cost savings: $86K 1 McLearen, L. J. (2015). Additive Manufacturing in the Marine Corps . NPS. p. 45 13
Air Force Possibility to scan and duplicate parts that are no longer manufactured (B-52) 1,2 • 1 Parker, J. (October 19, 2015). Planning a larger role for 3-D printing. Af.mil. 2 Forest, B. D. (March 22, 2017). The future of additive manufacturing in Air Force acquisition. Air University. 14
Industry Perspective Lockheed Martin “Prediction: AM Structures designed for maximum strength to weight ratios will evolve and analysis methods will improve to help certify them as “safe for manned aircraft”. Unmanned vehicles: Sky’s the limit…. “ Skeehan, M. (2014). Additive manufacturing: Changing the way we build and test aircraft . Presentation at the 2 nd Additive Manufacturing for Defense & Aerospace. Right click on picture – Acrobat Document Object - Open 15
Industry Perspective Boeing “AM will dominate tooling” claims Christodoulou, and to illustrate his point he describes a BAAM tool at Boeing that reduced build time to days from weeks, and cost by up to 70%. Pointing to a slide showing the Guinness Record holder for the largest 3D printed object he says, “we don’t do demo tools, this is a production tool for the 777X.” Petch, M. (February 28, 2017). Insights into additive manufacturing at Boeing with Leo Christodoulou . 3D Printing Industry.com. “Optimizing additive components will not be possible without sufficient understanding and redesign of the entire system design as a whole.” Aston, R. (November 2017). 3D printing done right . Boeing. Researchers at Oak Ridge National Lab developed a 3D-printed version of a “trim-and-drill” tool that Boeing uses to build the wings on its passenger aircraft. Adams, P. (August 29, 2016). The World’s Largest 3D Printed Object. U.S. Dept. of Energy. 16
Industry Perspective Northrop Grumman “We’ve started seeing lately that AM is more than just engineering and manufacturing people; quality people and drafters need to be involved in the process. “We’re incorporating procurement, supply chain. They need to be brought into the fold as well, because this is brand new technology for them,” and questions come up, such as “what is this filament stuff? How do I best order that? So now we are explaining to them how AM works, so they can do their job more effectively.” Brune, B. (August 10, 2017). Northrop using AM to efficiently make coldplates, cable clamps, more . Advanced Manufacturing. This kit, which is used to modify aircraft in the field, allows Northrop Grumman technicians to use minimal manual labor in what traditionally would have been major teardown-and-rebuild operations. Northrop Grumman’s uses 3D Systems SLA additive manufacturing technologies . (January 15, 2017). Evolv3D. 17
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