Rapid Manufacturing

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Rapid Manufacturing Repair Phase II a NCMS-CTMA
Program Using Layer-based Manufacturing
technologies to provide rapid solutions to
readiness needs and legacy part availability
Presented by Mark Tobler, General Pattern
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(No Transcript)
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RMR Phase II
On-going Activities
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Benchmarking State of the Art
Rapid Prototyping, Layer Based Manufacturing Conce
pts Explained
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Benchmarking State of the Art
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Benchmarking State of the Art
EOS M270 Direct Metal Laser Sintering
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Benchmarking State of the Art
VIDEO OF A DMLS BUILD A laser sinters metal
powder together
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Benchmarking State of the Art
Castings using New Rapid Tooling Technologies
ProMetal RCT at Keyport Produces sand casting
molds and cores direct from CAD enabling
fabrication of molds and cores that are
oftenimpossible to create by conventional means
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Benchmarking State of the Art
Castings! From Cad to Part
ProMetal Sand Mold Built By NUWC
Digital Mold Design
Castings delivered to TRF from NFPC
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Advanced Digital Manufacturing
Layer-based Manufacturing / Rapid Manufacturing /
Additive Manufacturing
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Advanced Digital Manufacturing
SYSTEM SPECIFICATIONS SLS Machines
SLS MACHINE
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Advanced Digital Manufacturing
VIDEO OF AN SLS BUILD A laser sinters plastic
powder together
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Advanced Digital Manufacturing
Selective Laser Sintering (SLS) Applications
DirectParts cable routing cooling
ducts fasteners connectors
NCMS Rapid Manufacturing Repair
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Advanced Digital Manufacturing
Metal Laser-Sintering (DMLS) DirectPart Metal
Prototype or Part in 2 Days

• Requirement
• Fully functional metal prototype
• for drive train
• Delivery time as soon as possible
• Solution
• DirectPart by DMLS
• EOSINT M 270 with
• DirectMetal 20
• Result
• Part delivered two days after
• receiving data

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Material Development

Metals
LENS Laser Engineered Net Shaping
EOS Direct Metal Machine
Arcam Electron Beam Melting
Laser and Electron Beam based manufacturing using
metal powders for production of prototypes and
end products, tooling and inserts directly from
CAD.
Titanium, Tool Steel, CrCo, Stainless Steel,
Aluminum, Inconel
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Material Development
Plastics
SLS Powdered Plastics
FDM Extruded Plastics
UV Cured Plastics
Nylon 11 Glass filled Nylon Aluminum Filled
Nylon Carbon Fiber Filled Nylon Polystyrene
Polycarbonate ABS Polyphenylsulfone PPSF
Water Clear Photopolymer Various durometer
Photopolymer Mineral Filled Photopolymer ABS-like
Photopolymer Investment Casting Photopolymer
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Material Development
Direct - Legacy Part Fabrication Repair
Indirect - Castings from ADF-RP Tooling
Official Approval to Use New Technology
Many ADF-RP technologies can produce tactical
quality parts, but getting official approval to
use parts is difficult. Propose to work with
approving officials in this phase to streamline
approval process.
SAE/AMS 4999 is the only current spec addressing
RM-type metal material
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Software Data Capture
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Software Data Capture
Amber A Study in Data Capture
RMR TEAM DATA CAPTURE STUDY The Part, Amber,
Was Subjected To Several Scanning Processes
RMR Team Compared Accuracy and Cost of 5 Systems
RMR TEAM DATA CAPTURE STUDY The Part, Amber,
Was Subjected To Multiple Scanning Processes
MACHINED ALUMINUM TEST SAMPLE Used as a Standard
Specimen Honeywell Kansas City Plant
COMPARING THE PROCESSES Vendors scanned the part,
filled out a questionnaire, and returned that
info to the group
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Technology Transfer
RMR IIRapid Manufacturing and Repair
Initiative Studying Applications Implementing
Process Capabilities
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Technology Transfer

Replacing Legacy Hardware using rapid tooling
Tooling is hard to get and expensive for low
quantity runs. Some Foundries often no quote
small quantities. Some Vendors increase prices to
unreasonable levels.
Typical Process Part was reverse engineered to
create a CAD model, then the CAD model was used
to create new ADF-RP patterns used to make new
castings.
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Suction Casing
Casing is for a Seawater Service Pump, Southeast
Regional Maintenance Center, Mayport, FL

• Cost for 3 casings 6,620.75 each (19,862.25
  total)
• Limited supplier of part
• Material Bronze (QQ-C-390)
• Part subject to excessive corrosion

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Tapped Hole Breaking Through
Badly Corroded Vane Thru Bore
Inside Diameter Badly Washed Out
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Technology Transfer
Reverse Engineered Part Using Faro Arm to gather
geometry to build CAD Model
Eroded, Washed out Area
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Technology Transfer
Side Profile Scan
Scanned Part Geometry
Finished CAD Model
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Technology Transfer
Castings! From Cad to Part
ProMetal Sand Mold Built By NUWC
Digital Mold Design
Castings delivered to TRF from NFPC
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Technology Transfer
Machined Casings to Plan Dimensions
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Technology Transfer
Final Cost Around 1,792.00 EachTotal Savings
Per Part 4,828.75

• Performed final machine work
• Passed hydrostatic testing
• Parts installed on pump
• Job Complete

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Case Studies
RMR IITeam Case StudiesExamples
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COVERS BREAK DURING REFURB TRF Reverse Engineered
into CAD Raytheon Printed the Patterns
SURFACE CRAFT BRAKE HOUSING TRF Kings Bay for
SEMC Mayport
Quick Cast Technology Transfer to Depots Case 4
RESULTING RAPID CASTING TRF-KB Final Machined New
Casting is Higher Quality
RESULTING COST SAVINGS
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SUBMARINE GALLEY BUTTON COVER TRF Kings Bay,
Georgia
COVERS NEED REPLACING OFTEN Vendor Requires
Complete Assembly
Rapid Tool Technology Transfer to Depots
RESULTING RAPID TOOL EFFORT TRF-KB Can Order in
Lots of 50. Material Is Actually Stronger As Well.
RESULTING COST SAVINGS
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Rapid Manufacturing Repair ProgramCase Study
Vacuum Cone - 48k per year Cost
Avoidance/Readiness Improvement Potential - for
qty of 4 items

• Problem/Challenge Vacuum Cone, NSN
  4310-01-119-5383. OEM is expensive
  unresponsive. Cost is 30K, lead time 48 weeks.
• Solutions/Results Reverse engineering part,
  created CAD model of part, along with casting
  risers, runners, gating,etc. Printed mold using
  Prometal S15 system, cast parts at local foundry.
  Cost 18K, lead time 8 weeks.
• Benefit/Impact
• With much quicker lead time, parts can be
  produced more just in time, versus big orders
  annually. Better serves emergent, unexpected
  needs
• 48K savings annually based on 4 units per year

Contacts/Learn More About It Kyle Morris,
NUWC-Keyport, 360-396-1939
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Rapid Manufacturing Repair ProgramCase Study
Vacuum Rotor - Cost Avoidance/Readiness
Improvement Potential, Just-in-time capability
(40wks)

• Problem/Challenge
• Vacuum Rotor NSN 4320-01-064-7594 OEM is
  expensive unresponsive. Cost is 19K, lead
  time 48 weeks.
• Solutions/Results
• Part reverse engineered and CAD model created by
  TRF-Kings Bay. Mold modeled at NUWC-Keyport,
  and mold will be poured by Naval Foundry
  Propeller Center (NFPC) Printed mold using
  Prometal S15 system, cast parts at local foundry
  Cost varies based on RP solution, lead time 8
  weeks.
• Benefit/Impact
• With much quicker lead time, parts can be
  produced more just in time, versus big orders
  annually. Better serves emergent, unexpected
  needs
• 20K savings annually based on 4 units per year

Contacts/Learn More About It ____KPT or TRF____
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Rapid Manufacturing Repair IICase Study
Vacuum Lobe - 56k per year Cost
Avoidance/Readiness Improvement Potential-
Just-in-time (40 wks)

• Problem/Challenge
• Vacuum Lobe NSN 4310-01-119-5384 OEM is expensive
  unresponsive. Cost is 35K, lead time 48
  weeks.
• Solutions/Results
• Reverse engineering part, created CAD model of
  part, along with casting risers, runners,
  gating,etc. Printed mold using Prometal S15
  system, cast parts at local foundry. Cost 21K,
  lead time 8 weeks.
• Benefit/Impact
• With much quicker lead time, parts can be
  produced more just in time, versus big orders
  annually. Better serves emergent, unexpected
  needs
• 56K savings annually based on 4 units per year

Contacts/Learn More About It ___KPT or TRF_____
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Rapid Manufacturing Repair ProgramCase Study
Vane Bending Tool - 9k per year Cost
Avoidance/Readiness Improvement Potential - Days
vs. weeks

• Problem/Challenge
• Vane bending tool is very complex to machine,
  requiring multiple Electro-discharge machining
  (EDM) operations.
• Solutions/Results
• Part was made directly from a CAD model of the
  part using direct metal laser sintering (DMLS)
  EOS M270 system.
• Benefit/Impact
• Part produced in days vs. weeks or months
• Machining part from billet would have been 10K.
  Metal printed part is 1000

Contacts/Learn More About It _General Pattern or
KPT_______
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Rapid Manufacturing Repair ProgramCase Study -
Suction Cover 3,976.50 Per Part Savings

• Problem/Challenge
• Cost from vendor 4,844.00
• Lead time 16 weeks or longer to procure part
• Difficult to cast material (288 Monel)
• Some Foundries often no quote small quantities
• Solutions/Results
• Reverse Engineer part, create CAD Model and STL
  file at TRF
• Casting pattern built by UTC Pratt Whitney
• Able to choose foundry that produces quality
  parts of hard to find materials
• Reduce lead times
• Benefit/Impact
• Significant dollar savings by using Rapid
  Manufacturing process
• Avoid paying for over priced parts

Contacts/Learn More About It Gary McMillan TRF
Kings Bay [phone] Randy Jeffcoat TRF
Kings Bay [phone]
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Rapid Manufacturing Repair ProgramCase Study
- Vacuum Pump Rotor 15,370.87 Per Part Savings
Potential

• Problem/Challenge
• No replacement parts in supply system
• Part cost 18,792.87 when available in 2006
• Some Foundries will not pour small lots
• Rotor material is highly corrosive to salt water
• Currently repaired by electroplating if possible
• Solutions/Results
• Replicate part using seven-axis CMM
• Create CAD and STL files
• Build FDM Model to verify part geometry
• Email STL file to NUWC for Mold Printing
• Pour Casting
• Ship Casting to TRF for final machining
• Benefit/Impact
• Cost for newly cast part around 3,422.00
• Part files available to cast future parts
• Now have alternatives to purchasing overpriced
  parts

Contacts/Learn More About It Gary McMillan TRF
Kings Bay [phone] Randy Jeffcoat TRF
Kings Bay [phone]
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Rapid Manufacturing Repair ProgramCase Study
HELICOPTER HANDLE, DLANAWCWD CHINA LAKE - 1.4
MM Cost Avoidance/Readiness Improvement

• Problem/Challenge
• The Defense Logistics Agency (DLA) provides
  logistics and support to the warfighter.
• DLA supplies weapon systems spare parts and end
  items and manages almost 1.8 million different
  types of spare parts.
• DLA is attempting to eliminate sole sourced items
  in order to reduce cost and expedite delivery.
• The handle portion is cast aluminum.
• It is difficult and expensive to identify casting
  vendors interested in manufacturing small lots
  because of the cost and schedule ramifications
  with respect to developing molds and patterns.
• Solutions/Results
• Reverse engineer components
• Use RP to deliver molds/patterns directly to the
  vendor
• Elimination of lead time for the vendor to make
  molds/patterns
• China Lake provided a prototype and a quantity to
  continue to enable the fleet to operate
• Elimination of the sole source situation should
  lead to further cost reduction.
• Benefit/Impact
• Reduced cost and schedule of handle assembly
• Cost Avoidance of approximately 1.4 Million

Contacts/Learn More About It John
Johnson NAWCWD China Lake [phone]
Tim Froehner NAWCWD China Lake [phone]
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Availability Readiness

• Emerging layer-based manufacturing processes and
  materials offer possible solutions
• Building layer-based manufacturing capability
  within the organic maintenance facilities offers
  ready access to these solutions
• Streamlining the approval / qualification
  processes offers ready implementation

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Successful Team

All Members of RMR Team donate their time to
solve the problems of others
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2005 Defense Manufacturing Excellence Award
Winner
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Join the Team

• Taking full advantage of evolving technologies
  is best done by being part of the Evolution
• Connie Philips
• NCMS Program Manager
• conniep_at_ncms.org
• 386-445-2785