Boeing 3D printing - technology readiness levels (TRL) 2006

BOEING is a trademark of Boeing Management Company.Copyright © 2006 Boeing. All rights reserved.

11/17/2006Filename.ppt | 1

Steps to Improve Direct ManufacturingReadiness Levels

Jeffrey DeGrangeSenior Manager – Advanced Manufacturing Research & DevelopmentSt. Louis, Missouri USA

EuroMold 2006Frankfurt, GermanyDecember 1st, 2006

Copyright © 2006 Boeing. All rights reserved.


Digital Manufacturing Technologies

SelectiveLaser

Sintering

Stereo-lithography

R.E. – ATOSScanning

LaserTracking

FusedDepositionModeling

LaserProjection

EBM-DirectMetal

SLG50031993-043.ppt



Use of Digital Information to Grow Parts

Selective Laser Sintering (SLS) Uses a Computer Controlled Laserto Construct Physical Objects Directly From a 3-D Solid Model Using Powdered Materials.

Process Overview1. Create 3-D Model Base Definition (Unigraphics, CATIA, ProEngineer)2. Electronic Delivery of the 3-D Model to SLS System. 3. 3-D Model Sliced Into Ultra-Thin 2-D Layers and Part Program Created.4. Laser Will Sinter Loose Powdered Material Together by Drawing and Filling the Cross-

sectional Cut for Each 2-D Layer.5. Repeat Process for Each Individual Layer Until Object Is Complete.6. Remove Objects From Bed of Powder.



Stereolithography Applications

Wind Tunnel Test Articles

Fit Check Articles

•High Accuracy (+/-0.003”)•Materials ranging from high modulus to Elastomer replicates•Loaded materials available : Ceramics, Metallic•Known wind tunnel scaling factors



Stereolithography Development Work

• Supplier Material Development• Low Cost Metal Plating

Flight Simulator Control Sticks

Metal Plated SLA



Selective Laser Sintering Applications

FABRICATED SLS DETAILS3D CAD MODEL

ASSEMBLED DRILL PLATE

POWER FEED DRILLING USING SLS DRILL PLATE



Selective Laser Sintering Applications

Environmental Control System Ducting on military aircraft

Copyright © 2006 The Boeing Company. All rights reserved

• Reduced Part Count• Flexible Design• Reduced Cost• No Tooling• Increased Cycle Time



Selective Laser Sintering Development Work

• Larger Build Chamber Machines• Flame Retardant Material for FAA Requirements




Fused Deposition Modeling Applications

• Quick Turn-around of Polycarbonate, ABS, and PPSF components• Sparse Fill feature offers rigid, lightweight components• PPSF is a high-temperature plastic (HDT=372° F)

Assembly tool for short run repair workLarge Scale Trim Tool

and Holding Fixture




Ground support equipment and toolsBox Subsystem Simulators





Composite FabricationTooling



Electron Beam Melting

Electrons are emitted from a filament which is heated to > 2500° CThe electrons are accelerated through the anode to half the speed of lightA magnetic field lens brings the beam into focusAnother magnetic field controls the movement of the beamWhen the electrons hit the powder kinetic energy is transformed to heat.The heat melts the metal powder



Electron Beam Melting Development

• Low cost Titanium powder• Better control systems• Heat Transfer modeling techniques



Where Is the Technology Going?

Evaluation of Direct Nylon Components for Commercial Applications

Meet Flame & Toxicity Requirements

Continue the Advancement of Direct Manufacturing of Thermoplastic and Metal Materials

Production to Additional Programs and Applications

Mainstream the Use for Rapid Tooling and Post-Production Support Applications

Enables the Ability to “Design Anywhere, Build Anywhere”

Direct Manufacturing Technology will Fundamentally Change How WeThink About Design, Manufacture and Support



Example for Production Applications Multi-Functional Designs

New (SLS) Configuration

Previous (Kevlar/Rotomold)Configuration

Attach Straps Eliminated• Part Count Reduction• Quick & Easy Installation

Multiple Ducts Combined to Single-Piece Duct

Conformal Shapes Achieved and Internal Flow Features Added



Example for Production Applications The Value of Direct Manufacturing

• Engineering Design:• Direct from 3-D Model Base Definition• Design and Build Flexibility

• Production:• Eliminate non-recurring tooling costs• Lower recurring unit part costs• Faster part delivery times• Supplier flexibility• Direct Fabrication:

• 50% Cost Reduction• 67% Cycle Time Reduction at

Minimum• Product:

• Reduced part count and weight• Lower inventory and transportation

costs• Improved Life Cycle Product Costs



Production On Demand

Out Production Parts

Reproduced(Prototype)

Dynamic Supply

Chaining

Coexistence of Typical Productionand Production On-Demand

DevelopedBuild-toPackage

Re-Modeled

Scanned Results

Sample Part

Return to Agenda



Qualification & Certification Definitions

• Qualification- Focus on Controlling Variables Within Acceptable Limits- Includes Materials- Included Processing

- Also Covers Equipment Certification- Intent is Demonstrating a Stable Material and Process for Use on Applications

- Three to Five Batch Qualifications for Each Test to establish B-Basis Material Allowables

• Certification Focus is on the Application- Point Insertion- General Insertion



Candidate Application Selection



Platform Evaluation Methodology

Step 1

Step 2

Step 3

Step 4

• Tailor AIM-C Readiness Level Guides Towards Direct Digital Manufacturing

• Process/Equipment• Materials

• Establish More Specific Questions to Translate Exit Criteria Into Relative Items


• Assess Maturity In Each of the Categories/ Groups/Items


• Establish The Specifics For Conformance Activities to Meet Maturity Exit Criteria with the Selected Technologies and Applications

• Process, Equipment, Matl’s, Structures

TRL’sxRL’s

Questionnaire

TechnologyAssessment

ConformancePlanning



Initial Overall Technology Readiness Level (TRL) Guide



Key Areas- Education of Design Communities

• Remove the ‘Cuffs’ of Design For • Manufacturing & Assembly (DFMA)

• Complexity is Ok.. Even Good!

• Propagate the Design For Function (DFF) Design Mentality

• Encourage the Adaptation of Designing Multi-Functional Parts• Encourage sub-systems teams to work together

• Industry Service Specifications (SAE, ISO, AMS, etc.)

• Universities Must Begin to Teach the Principles of Direct Manufacturing



Key Areas- System Development Needs

Platform Up-time Must Approach 90%

Product/Process Consistency• Thermal Consistency• Dimensional Consistency

Production Capable Operational StrategiesOff-line Cool Down/Warm UpPallet Shuttle System Approach

Platform Modularity to Improve ServiceabilityShaping Sub-systemsEnvironmental Control Sub-systems

Software CapabilitiesProcess Monitoring/Data Acquisition SoftwareSelf Calibrating CapabilitiesOpen Architecture Code (Not Necessarily Control algorithms)



Required Materials Advancements

• Incoming Product Consistency• Batch and lot traceability• Contaminant free material

• Reasonable Product Cost • The product must be available in bulk buys• Sellers must add value to the product

• Supply Chain Capable of Delivering Production Quantities• Pounds Consumed Substantially Increased with the

Number of Applications

• Improved Performance Materials• Temperature, Stiffness, Strength, Toughness, Etc.

• Base Level Standardization of Property Reporting



Required Materials Advancements

• Improved Performance Materials• Isotropic properties• Stiffness (at elevated temperatures)• Strength (at elevated temperatures) • Toughness (at low/room temperatures)• UV Resistance

• Base Level Standardization of Property Reporting• Tensile• Impact• Hardness

• Scientific Understanding of Material Characteristics and Processing Characteristics• Explanations of empirical phenomena• Develop materials performance prediction tools



Key Areas- Industry Short-Comings

• Reliable, Prompt Maintenance• Machines cannot be down for extended periods• Selected spares stock on-site to reduce delays• Train on-site maintenance personnel on some

recurring calibrations or repairs to eliminate down time

• Reasonable Cost of Maintenance Contracts• On-site spares stock included in the maintenance

contract• Bulk buy contracts for vendors with multiple

machines

• Develop Concise Troubleshooting Procedures• Eliminate the ‘Shot Gun’ approach to repairs• Reduce down time as well as cost for the OEM



Process Repeatability

• Dimensional Accuracy and Repeatability

• Requirements for Acceptance:

• Build test article (shown left) in 9 locations within build chamber; diagonally across the x-y top, middle and bottom. All measurements between cubic facets must be within ±.007”.



Development of World Wide Supply Base

Revenues from rapid prototyping / rapid manufacturing industry reached $705.2M in 2004 and is growing

Direct manufacturing for Boeing depends on collaboration with supplier networks across national borders

Over (1170) SLS machines currently installed world wide

High-speed and large-frame machines enhance productivity and reduce part cost

Boeing standards for SLS manufacturing and quality control are well established

Certification of SLS manufacturing centers in USA, Europe, and Asia is feasible for production



Certain Challenges Remain

Bigger Batch Sizes Logistics Flow

New Part`s Designs

Higher AutomationLarger Part Sizes

Part‘s Homogenity

Faster Production New Designs

Have to be reflected in ....

……………

Machine Design

Quality Control & Standards

Material Properties

Process Technology

Production Process &

Control

Parts Design & Engineering



Strategic Vision for Direct Manufacturing

Capable

Broader Marketplace

ReliableRepeatable

Reduce Cost & Part CountContinuous

Improvement

Production Capable Direct Manufacturing System



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