Composites Tooling Solutions Webinar Dan Campbell | Aurora Flight - - PowerPoint PPT Presentation

Cost-Effective Additive Manufactured Tooling for Composites

Tooling Solutions Webinar

2 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY

Dan Campbell | Aurora Flight Sciences Research Group Lead Timothy Schniepp | Stratasys Leader, Tooling Solutions

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Distribution A – AFRL Public Relations Case Number: 88ABW-2017-1554

Cost-Effective Additive Manufactured Tooling for Composites

Aurora Flight Sciences Dan Campbell

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Distribution A – AFRL Public Relations Case Number: 88ABW-2017-1554

Outline

• Background and Previous Work: Additive for Composite Tooling
• Evaluation Tool for Air Force Research Laboratory
• Design Requirements and Considerations
• Evaluation Results
• Conclusion and Recommendation
• Thoughts on Tool Repairability

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Distribution A – AFRL Public Relations Case Number: 88ABW-2017-1554

Background and Previous Work: Additive for Composite Tooling

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Distribution A – AFRL Public Relations Case Number: 88ABW-2017-1554

Large Multi-Piece Additive Tools

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Distribution A – AFRL Public Relations Case Number: 88ABW-2017-1554

Sub-Scale DARPA X-Plane Structure

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Distribution A – AFRL Public Relations Case Number: 88ABW-2017-1554

The results presented were sponsored by the Air Force Research Laboratory under contract F48650-11-D- 5703, titled " Low Cost, Fast Response Tooling"

Design Requirements and Considerations for Additive Tooling

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Distribution A – AFRL Public Relations Case Number: 88ABW-2017-1554

15.5” 27” 16” 1.5 x 1.5” Inspection Pocket

• Female tool of complex curvature
• Tool must withstand multiple

cycles of 350 °F at autoclave pressures (90 psi).

• Tool tolerance requirement of

+/- 0.015 inches

• Tool surface roughness

requirement of 125 µin

Baseline Tool Geometry and Requirements

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Distribution A – AFRL Public Relations Case Number: 88ABW-2017-1554

Technical Approach

Our development approach took advantage of the low-cost and fast manufacturing process associated with additive manufacturing:

– Design – Print – Scan – Autoclave – Scan – Repeat

8 tools were printed, measured and tested:

– Tool #001 Block tool design. Full size, sub-section. – Tool #002 Block tool design. Full size, sub-section. – Tool #003 Block tool design. Full size, sub-section. – Tool #004 Shell tool design. Full size, sub section. – Tool #005 Shell tool design. Full size, sub section. – Tool #006 Shell tool design. Full size, full section. – Tool #007 Shell tool design. Full size, full section. – Tool #008 Shell tool design. Full size, full section.

Low Cost Fast Manufacturing

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Distribution A – AFRL Public Relations Case Number: 88ABW-2017-1554

Manufacturing Equipment and Tooling Material

Fortus 900mc™ – in service since 2008 ULTEM™ 1010 Resin Unfilled – commercially available since 2015

*ULTEM 1010 Resin Filled (or similar high temp polymer) not evaluated, but an attractive option for this application once commercially

available

ULTEM 1010 Resin

ULTEM™ is a registered trademark of SABIC or affiliates or subsidiaries.

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Distribution A – AFRL Public Relations Case Number: 88ABW-2017-1554

Cost Model Definition

Part Cost = Material usage * $/cubic inch + # of hours * $/hr

The majority the tool’s cost is the cost of

• material. The machine cost is the cost to

the owner, wherein Aurora assumes amortization over five years at a 80% utilization rate. If the tool required post processing, labor cost was added in at $110/hr and surface film material cost at $4.68/sq ft. Aurora’s Fortus 900mc Cost Breakdown

• $11.41/hr capital cost
• $1.53/hr warranty & repair cost
• $1.20/hr electrical cost

Material Type Cost $ / Cu-in ABS-M30™ $3.80 ASA $3.80 FDM Nylon 12 $4.30 PC $4.30 PC-ISO™ $4.30 PC-ABS $4.30 PPSF $7.45 ULTEM 9085 resin $7.45 ULTEM 1010 resin $7.45 SR20 $4.13 SR30™ $3.91 SR100™ $4.89 S110 $4.89 S1 $7.45 PC-BASS $4.30 PPSF-BASS $7.45 Machine Type $ / Hr Fortus 400mc™ $5.27 Fortus 900mc $14.05

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Distribution A – AFRL Public Relations Case Number: 88ABW-2017-1554

Tool Design Methodology

Baseline, Block Tool Shell Tool

• Surface bag, table-top bag,
• r envelope bag
• Requires more material, thus

higher cost and print times

• Requires less material, thus

lower cost and print times

• Easer to size and design tool,

less structural analysis required

• Risk of bag bridging and

folding tool

• Envelope bag required

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Distribution A – AFRL Public Relations Case Number: 88ABW-2017-1554

Bagging Methods

Surface Bag Envelope Bag Table Bag

Envelope bagging preferred:

• Does not require a completely sealed surface
• Less labor intensive (no or minimal pleats)
• Easily possible due to lightweight nature of tools
• Care must be taken to not bridge the bag when applying vacuum

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Distribution A – AFRL Public Relations Case Number: 88ABW-2017-1554

Surface Preparation – Film Application

• The preferred approach for this

program was using an adhesive- backed fluoropolymer film.

• Application was a mature

process that achieved repeatable and reliable results.

• The process initially exceeded

surface roughness requirements before cure, however print- through was observed after subsequent cures. This could be remedied with a thicker film or fiberglass reinforced film.

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Distribution A – AFRL Public Relations Case Number: 88ABW-2017-1554

Metrology Collection

• Tolerances – CMM Laser Scan
• Surface Roughness – Profilometer, record worst value, Ra value
• Print Time – Calculated from the tool path file
• Mass – Calculated from tool path file and validated via calibrated scale
• Surface prep time – Timed, assume no learning curve

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Distribution A – AFRL Public Relations Case Number: 88ABW-2017-1554

Tool Design, Fabrication and Test

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Tool Evaluation Progression

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Distribution A – AFRL Public Relations Case Number: 88ABW-2017-1554

Cost and Build Time Evolution

Tool 1 to 2 = material removed Tool 3 to 4 = block design to shell design + larger tip size Tool 4 to 5 = single-piece to multi-piece tool Tool 5 to 6 = multi-piece to single-piece tool Tool 6 to 7 = addition of stabilizing wall during print

$- $2,000 $4,000 $6,000 $8,000 $10,000 $12,000 1 2 3 4 5 6 7 8 9 Tool Cost Tool Build Time build days tool cost ($)

1 2 3 4 5 6 7 8

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Distribution A – AFRL Public Relations Case Number: 88ABW-2017-1554

Tool # 007

Printed stability wall allows us to achieve tolerance requirement.

Full Size Tool: $4,507, 2.4 day build

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Distribution A – AFRL Public Relations Case Number: 88ABW-2017-1554

Tool # 008

The Final Tool

Full Size Tool: $4,507, 2.4 day build

ASA support base (not to be cured) ULTEM 1010 resin tool Tooltec – surface film

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Distribution A – AFRL Public Relations Case Number: 88ABW-2017-1554

Additive for Composite Tooling

Using mature and commercially available equipment (Stratasys Fortus 900MC) and material (Stratasys ULTEM1010 resin), and following AFRL’s provided tool geometry, a tool was delivered with the following properties.

– $4,507 total cost to machine owner – 57.5 hours to build (no machining required) – One-hour of surface prep (includes application of film, aka Tooltec) – 16.5 lb tool weight – 31 µin max surface roughness, Ra (this number was measured before the first cure cycle) – +/- .030” tolerances – Multiple 350 °F, 90 psi cure cycles completed successfully

Tooling Using FDM and ULTEM 1010 Resin is Viable for 350 °F, 90 psi Processing

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Distribution A – AFRL Public Relations Case Number: 88ABW-2017-1554

Additive Tooling Recommendations

• Shell tool designs over a traditional block tool designs.
• Use unfilled ULTEM 1010 resin material if its coefficient of thermal expansion is tolerable or the

tool may be designed to accommodate the expansion.

• Use a solid geometry for the shell tool design. If it’s a unique tool design that benefits from

sparse-fill, hexagram core geometry is recommended, however FEA and/or testing may be required.

• Ideally build with a large tip size paired with thicker Tooltec surface film to achieve an

acceptable surface finish and surface seal.

• Epoxy repairs recommended using Hysol-9394 epoxy. When repairing complex, compounded

surfaces, a matched, printed pressure caul is useful.

• Leverage the design freedom additive provides and incorporate additional features if possible

(thermocouple pathways/mounting, shop aids, etc.) It’s important to take advantage of the design freedom that traditional manufacturing methods do not allow for.

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Distribution A – AFRL Public Relations Case Number: 88ABW-2017-1554

Reference - Tool Repairability

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Distribution A – AFRL Public Relations Case Number: 88ABW-2017-1554

Tool Repair Evaluation

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Stratasys Composite Tooling Solutions

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• Capable, cost-effective lay-up tooling in days, not months
• High-temperature, autoclave cure-compatible solutions
• Robust, user-friendly sacrificial tooling solutions
• Highly effective for ancillary tooling
• Machining, inspection & bonding fixtures, drill guides, etc.
• Comprehensive Design Guides are available to ensure success

http://www.stratasys.com/solutions/additive-manufacturing/tooling/composite-tooling

FDM Composite Tooling

Design Build Prep & Seal Release & Lay-Up

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Tooling Applications for Composites

Composite Lay-Up Tools Coordinated Tool Family Sacrificial (Wash-Out) Lay-Up Tools

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Large Tooling Projects in Development

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What Comes Next for Composites

Tomorrow Today

Tooling FDM Composite Parts

Robotic Composite 3D Demonstrator Infinite Build 3D Demonstrator

Questions?

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Keep the conversation going…

Stratasys Tooling Solutions http://www.stratasys.com/solutions/additive-manufacturing/tooling

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Distribution A – AFRL Public Relations Case Number: 88ABW-2017-1554

Tim Schniepp Leader, Stratasys Tooling Solutions Timothy.Schniepp@stratasys.com

THANK YOU