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

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A Value Chain Designed for Repeatability

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.

3 Conceptualization – Advisory Services assist clients with the inception of an idea and establish expectations for what is and isn’t possible with Additive Manufacturing Design & Part Optimization – Engineering Services provide specialized expertise in additive manufacturing design, improve design for better performance / mass reduction Metallic 3D Printing – Manufacturing Services emergence of initial concept or

• ptimized part from initial prototype

through serialized production – contract manufacturing Post Processing – Finishing Services post- build surface treatment, heat treating, HIPing, and traditional machining and final finishing as required Metallurgy Lab & Inspection – Lab Services test coupons, metallurgical examination for performance, hardness testing, and dimensional quality assessment - R&D of new materials Certification & Data Analysis – Documentation Services collection of quality and build inputs, data analysis and documentation for part qualification and certification

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Mo Morf3D’s Ma Market Offering

Ap Applica 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

• In

Increased performance and functionally integrated pa parts

• Ab

Ability to manufacture complex geometries

• Li

Lightweight opportunities – La Lattice, Hollow St Structures

• Im

Improved mechanical properties

• Su

Supply Chain Efficiency

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Di Disruptive De Design

5

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Di Disruptive De Design – To

Topology Optimization

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41% ¡Weight ¡Reduction, ¡increased ¡stiffness 79% ¡Weight ¡Reduction, ¡increased ¡frequency ¡response 45% ¡Weight ¡Reduction, ¡increased ¡frequency ¡& ¡stiffness

Benefits realized by the use of Additive Manufacturing:

• Dramatic weight reduction
• Increased stiffness
• Increased performance
• Rapid design iterations
• Reduced payload expense
• Volumetric efficiency

(current payload costs reported by NASA are $20,000/kg)

Original Design 1.6kg 88.7Hz 163MPa Final Design 0.936kg 91.5Hz 103MPa

Improved Performance and Weight Reduction of 41%

Bi Bionic Design & Optimization

(C (Customer: European Space Agency ESA - Se Sentinel 1 Sa Satellite )

Pa Path th To

• Qualification
• n

Ne Nesting of Flight Hardware with in-pr process sampl ples

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Ho Holistic Qualification Process

Ho Holistic Process designed for Additive Manufacturing to insure structurally so sound components. s.

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Me Mechanical & Ma Material Verification

De Detail of the Fracture Plane (Horizontal Spe pecimen) Pore in fracture plane is ~30 micron diameter < critical pore size of 150 micron Qu Qualification Testing Methods: Tensile Testing, SEM Microstructural Analysis, CT Geometric Analysis, CT Scanning for Internal Defects, Sine Testing

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CT CT Scan n and nd Geometric Validation

Maximum deviation = 280 micron (non critical surface)

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

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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?

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Ex Explore the options that create the foundation for the Additive Man Manufac 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

EV EVOLVE E – Pl Plan & Design

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Re Realize the possibility of what is next. EM EMER ERGE to to make it t real th through pr prototypi 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

EM EMER ERGE E – Pr Proto toty type & Operati tions

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In Innovation Center – El El Segundo, CA.

Unfair Advantage

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Digital Rendering

• 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
• ptimization
• Metallurgy Lab & Testing Equipment

Digital Rende ring

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Explosion ¡proof ¡enclosure ¡– 2 ¡EOS ¡M290 Engineering ¡and ¡Collaboration ¡Space ¡ Enabling ¡the ¡Future ¡– Summer ¡Interns

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Additive Smarts.