Additive Manufacturing Fundamental Concepts DAU Lunch & Learn - - PowerPoint PPT Presentation
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
Tuke Klemmt, MLS, Director Rashid Faraby, MLS Katherine Multop, MLS DAU Knowledge Repository https://identity.dau.mil/EmpowerIDWebIdPForms/Login/Krsite
DAU Lunch & Learn 02.07.2018 Dave Floyd, Moderator DAU FLD-LOG
Research dive into the literature – takeaways How services are implementing this technology Industry perspectives
Prepare a 3D model for printing Learn how to operate a 3D printer Lessons learned
Wrap-up Additional questions
Introduction
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.
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.
Goh, G., Agarwala, S., Goh, G., Dikshit, V., Sing, S., & Yeong, W. (2017). Additive manufacturing in unmanned aerial vehicles (UAVs): Challenges and
Langlais, R. Jr., Avdellas, N., Finfrock, C., Salley, R., & Newcomb, M. (November-December 2016). Separating hype from reality. Defense AT&L.
Validating Isotropy in SLA 3D Printing. (October 12, 2016) The porosity of a material and poor bonding between layers may weaken the overall structure of an additively manufactured
USAF wish to eventually fabricate in the field. Haria, R. (October 24, 2017). U.S. Air Force summons Synchrotron to investigate 3D printed layering. 3D Printing Industry.com. Residual stress is a result of heating and cooling, expansion and contraction, that occurs during the metal 3D printing
the printing material or substrate, defects, such as cracking in the part or warpage of the substrate, can occur. Molitch-Hou,
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.
“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
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.
https://youtu.be/_GlxVjAHofk
https://youtu.be/l7yrwGt6iFw
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.
“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.
– 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
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.
3d printed sprocket, on the right, made
plastic
Quadcopters capable of carrying cameras or other intelligence payloads 20-25 minutes flight time / $2,000 a piece / created by Ripper Lab (7th Marine Regiment)
1 McLearen, L. J. (2015). Additive Manufacturing in the Marine Corps. NPS. p. 45
F-35 Wind Tunnel Model Cost savings: $65K F-22 Cockpit Floor Cost savings: $86K
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.
“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 2nd Additive Manufacturing for Defense & Aerospace.
Right click on picture – Acrobat Document Object - Open
“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
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.
“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.
Scan Design Explore a 3D Library EINSCAN-SP Desktop 3D Scanner Blender Thingiverse 3D Structured Light Scanner AutoDesk MeshMixer GrabCAD OpenSCAD Yeggi Sculptris Pinshape Tinkercad (Online-based) MyMiniFactory
https://go.usa.gov/xnAsJ (00:45) https://go.usa.gov/xnAH3 (01:11)
ABS (Acrylonitrile Butadiene Styrene PLA (Polylactic Acid) Petroleum-based thermoplastic Thermoplastic based on plant or renewable resources (corn starch, sugar cane, capioca). Recyclable thermoplastic 100+ years to decompose Recyclable bioplastic. Biodegradable within 6-12 months Strong and Resilient Durable and high resistance to heat Brittle and tends to break Prone to warping/cracking over time Color may affect physical properties Absorbs moisture Smells like melted plastic fumes when printed May be toxic when melted or sanded Proper ventilation recommended Exudes honey/syrup-like odor Not toxic in solid form No ventilation necessary High print temperature (210-260 degrees C) Low print temperature (180 to 220 degrees) Inexpensive Cheap Typically used to print toys like Lego, computer keyboards, protective casing, etc. Engineering/manufacturing/professional plastic. Commonly used in food packaging and medical devices (screws, pins) Consumer/hobbyist/DIY plastic Plastic for pro-sumers
3D Printer Home DAU Headquarters Fort Belvoir, VA B207 Breakout Room 10 703.805.2255
https://www.dau.mil/cop/am/Pages/Default.aspx 26 AM Training Video Vignettes https://www.dau.mil/acquipedia/Pages/ArticleDetails.aspx?aid=000624f0-61dd-4982-bca3-122334e57a
University.
RDECOM.
United States Government Accountability Office.
Research Laboratory.
International Journal of Systems Science: Operations & Logistics.
Military Convoys. 3DPrint.com.
Print.com.