additive manufacturing - dau.mil · benefits • reverse engineer (scan) and duplicate obsolete...
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Tuke Klemmt, MLS, DirectorRashid Faraby, MLSKatherine Multop, MLSDAU Knowledge Repositoryhttps://identity.dau.mil/EmpowerIDWebIdPForms/Login/Krsite
Presentation Title
Additive ManufacturingFundamental Concepts
DAU Lunch & Learn02.07.2018
Dave Floyd, ModeratorDAU FLD-LOG
PRESENTATION AGENDA
Research dive into the literature – takeawaysHow services are implementing this technologyIndustry perspectives
Katie Multop
Prepare a 3D model for printingLearn how to operate a 3D printerLessons learned
Rashid Faraby
Wrap-upAdditional questions
Tuke Klemmt
Tuke Klemmt Introduction
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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.
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Benefit
Complex ShapesNOTE: 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.
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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, 63Langlais, R. Jr., Avdellas, N., Finfrock, C., Salley, R., & Newcomb, M. (November-December 2016). Separating hype from reality. Defense AT&L.
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Concern
Weak Bonding and Residual Stress
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 component. This makes it unsuitable for the replacement parts that 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 process. When residual stress exceeds the tensile strength of the printing material or substrate, defects, such as cracking in the part or warpage of the substrate, can occur. Molitch-Hou, M. (July 10, 2017). 7 Issues to Look Out for in Metal 3D Printing. Engineering.com.
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Army
• Grenade Launcher (RAMBO)1 https://youtu.be/VBXbtgwh89o• B-hut2 https://youtu.be/LjBS6b7ZeF8• MRAP valve stem covers3 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.
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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 hull1 – Disruptive Technology Lab and Oak Ridge National Laboratory
https://youtu.be/_GlxVjAHofk• MV-22B Osprey titanium link and fitting assembly for engine nacelle2
https://youtu.be/l7yrwGt6iFw• Trident II D5 Missile3 – 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.
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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.
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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
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, madeof Acrylonitrile Butadiene Styrene (ABS)plastic
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Marines
Nibbler
Quadcopters capable of carrying cameras or other intelligence payloads20-25 minutes flight time / $2,000 a piece / created by Ripper Lab (7th Marine Regiment)
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Air Force
• F-35 prototyping of fuselage and wing skins by Lockheed Martin1
• F-22 cockpit floor structural mock-up1
1 McLearen, L. J. (2015). Additive Manufacturing in the Marine Corps. NPS. p. 45
F-35 Wind Tunnel ModelCost savings: $65K
F-22 Cockpit Floor Cost savings: $86K
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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 2nd Additive Manufacturing for Defense & Aerospace. Right click on picture – Acrobat Document Object - Open
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Industry Perspective
“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.
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.
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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.
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Concepts & Kinematics
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3D Printing Workflow
Fused Filament Fabrication (FFF)/Fused Deposition Modeling (FDM) vs Photopolymers
Thermoplastic vs Thermosets Software is used to slice the 3D model into 2D layers Printing movement is in 2D one horizontal plane at a time
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4D Anybody?
Programmable smart objects which self-transform when subjected to energy. A project initiated by MIT Self-Assembly Lab in collaboration with Stratasys and
Autodesk.20
Cost
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3D Objects
Scan Design Explore a 3D Library
EINSCAN-SP Desktop 3D Scanner
Blender Thingiverse
3D Structured Light Scanner
AutoDesk MeshMixer GrabCADOpenSCAD YeggiSculptris PinshapeTinkercad(Online-based)
MyMiniFactory
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3D File Format
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3D in Action
https://go.usa.gov/xnAsJ (00:45)
https://go.usa.gov/xnAH3 (01:11)
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ABS (Acrylonitrile Butadiene Styrene PLA (Polylactic Acid)Petroleum-based thermoplastic Thermoplastic based on plant or renewable resources
(corn starch, sugar cane, capioca).
Recyclable thermoplastic100+ years to decompose
Recyclable bioplastic. Biodegradable within 6-12 months
Strong and ResilientDurable and high resistance to heat
Brittle and tends to break Prone to warping/cracking over timeColor may affect physical propertiesAbsorbs moisture
Smells like melted plastic fumes when printed May be toxic when melted or sandedProper ventilation recommended
Exudes honey/syrup-like odorNot toxic in solid formNo ventilation necessary
High print temperature (210-260 degrees C) Low print temperature (180 to 220 degrees)
Inexpensive CheapTypically 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
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Layer Extrusion & Print Resolution
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Lessons Learned
• Make Mistakes but learn how to avoid them
• Respect basic laws of physics
• Always use rafts and support material for overhangs and bridges
• Never Handle hot ends directly
• Don’t reinvent the wheel
• Have fun making 3D objects 30
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Additive Manufacturing – DAU Learning Assets
Additive Manufacturing Community of Practice (AM CoP)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
ACQuipedia
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Additive Manufacturing - References and Resources
• Bell, D., Fallat, J., Sterley, G., & Alsuhibani, E. (March 17, 2017). The Future of Additive Manufacturing in the U.S. Military. Air University.
• Booth, J. C., Whitley, M., Rudd, C., & Kranz, M. (December 2017). Material database for additive manufacturing techniques. RDECOM.
• Coyle, D. M. (September 2017). Analysis of additive manufacturing for sustainment of Naval aviation systems. NPS. • Fey, M. (2017). 3D printing and international security: Risks and challenges of an emerging technology. (PRIF Report No. 144).• Machi, V. (October 30, 2017). Defense industry moves toward multi-material 3d printing. NDIA. • Merritt, Z. (October 2015). Defense additive manufacturing: DOD needs to systematically track department-wide 3D printing efforts.
United States Government Accountability Office. • Newman, J. (June 8, 2017). Hitting print: Navy on board with additive manufacturing. Naval Aviation News. • Pepi, M. (October 2017). Towards Production of Additive Manufacturing Grade Metallic Powders on the Battlefield. U.S. Army
Research Laboratory. • Pour, M. A., Zanoni, S., Bachetti, A., Zanardini, M. & Perona, M. (2017). Additive manufacturing impacts on a two-level supply chain.
International Journal of Systems Science: Operations & Logistics.• Saunders, S. (February 16, 2017). Marine Corps Captain 3D Prints Water Bottle Prototype, Designed to Reduce Logistical Footprint in
Military Convoys. 3DPrint.com.• Saunders, S. (August 25, 2017). US Marine Designs 3D Printed Surveillance Drone at Fraction of Regular Cost. 3D
Print.com.• Veronneau, S, Torrington, G. & Hlavka, J. P. (2017). 3d printing: Downstream production transforming the supply chain. RAND. • Wilbanks, K. & Vadiee, A. (February 2017). Beyond prototyping: 3d printing in government contracts. The Procurement Lawyer.
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