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Distribution Statement A – Approved for Public Release
ADDITIVE MANUFACTURING
Dr. Jennifer WolkNaval Surface Warfare Center Carderock Division
Distribution Statement A – Approved for Public Release
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Distribution Statement A – Approved for Public Release
What is Additive Manufacturing?
Additive manufacturing (AM) describes a series of part manufacturing technologies that fundamentally differ from conventional subtractive machining processes. The different additive processes each possess unique advantages in materials and applications. The processes can broadly be categorized into the following eight groups:
• Binder Jetting1
• Directed Energy Deposition2
• Direct Write3
• Material Extrusion• Material Jetting4
• Powder Bed Fusion4
• Sheet Lamination4
• Hybrid Technologies
“The process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies.”
– ASTM International F42 Committee on Additive Manufacturing Technologies, 2009
1Biomimetic Structured Porogen Freeform Fabrication System for Tissue Engineering, Jack Zhou and Lin Lu, Drexel University2Image by rpmandassociates.com 3Image by nScrypt 4Images by custompartnet.com
Different processes utilize different materials/forms and can
result in different properties
Distribution Statement A – Approved for Public Release
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Distribution Statement A – Approved for Public Release
Advantages and ApplicationsAdditive manufacturing is generally suited for applications that meet the following criteria:• Low production volume• Complex part geometry• Expensive materials
AdvantagesApplications
Examples
Custom trim tools
Prosthetic foot
Shortened design time
Rapid part turnaround
Inexpensively obtain geometric complexity
Reduction in material waste
Limited tooling required
Reduced labor costs
Rapid tooling
Rapid prototyping
Rapid manufacturing
Repair
Electronics
• Custom fixtures• Injection molds• Sand casts• Trimming tools
• Design iterations• Geometric fit-checks• Scale models• Working prototypes
• In-house manufacture• Printed assemblies• Legacy part development
• Machining errors• Casting errors• Worn parts
• Embedded sensors• Structural health monitoring• Printed electronics
Over-machining repair
Circuits and dice
Design comparison
Distribution Statement A – Approved for Public Release
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Distribution Statement A – Approved for Public Release
Technology Gaps
• Design guide for each process• Printing systems, parts of systems, and
assemblies• Identification of properties that determine
when AM should be considered
Design
• Rapid qualification of parts• Database of material properties• Non-destructive evaluation of parts• Buy-in from shipyards and OEMs
Standards and Qualification• Database of parts that can be made using AM• CAD data storage • Integration of CAD files into COTs software• Handling of feedback data
Data Management
• Research in emerging AM materials (magnetics, electronics, etc.)
• Multi-material research (material gradients, embedded sensors, etc.)
• Repaired materials
• Real-time process monitoring• Equipment control• Material control• Modeling • Integration with other systems (i.e. 3D scanning)
Processes
Materials
The following are technology gaps identified in discussion with industry, academic, and other government personnel:
Distribution Statement A – Approved for Public ReleaseDistribution Statement A – Approved for Public Release
3D Model Print Part Post Process
Identified AM R&D Issues
*NSWCCD 61 foresees future research in these areas
•Cybersecurity•‘Design for AM’•File Database•File Integrity• IT Strategy• Model and Simulation
Package Development
• Material Properties• Microstructure• Procedure
Development• Residual Stress
Understanding• Tolerances
• Non-Destructive Evaluation/Defect Detection
• Qualification and Certification
• Material Storage• Material
Development
• Support Material Development• Support Material Removal• Intermediate Handling
• Closed Loop Feedback
• Improved Energy Sources
•In-situ Inspection• Optimize Parameters•Process Repeatability•Sensors/Build Data•Scalability
Distribution Statement A – Approved for Public Release
ADDITIVE MANUFACTURING AT NAVSEA WARFARE CENTERS
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NAVSEA Warfare Center Overview• Warfare Centers (WFCs) consist of seven Naval Surface Warfare Centers (NSWC)
and two Naval Undersea Warfare Centers (NUWC)• Supplies technical operations, people, technology, engineering services, and
products needed to equip and support the fleet and meet the warfighters' needs• Principle RDT&E assessment activity for surface ships, submarines, and
subsystems• Provides depot maintenance and in-service engineering support to ensure
system reliability• 2012 ASN RDA Memo: Importance of “DoN Scientists and Engineers perform or
participate significantly in these functions in the early stages of research and development (R&D). Examples include: engineering work in support of AoAs, in-house prototyping. . .”
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Distribution Statement A – Approved for Public ReleaseDistribution Statement A – Approved for Public Release
NAVSEA Warfare Centers Additive Manufacturing Working Group (AMWG) Meeting
Coordination Lead: NSWC Carderock
NAVSEA Warfare Centers AMWG Goals:• Define a strategic vision for the NAVSEA Warfare Centers in Additive
Manufacturing, including goals and a recommended path forward• Identify Warfare Center existing and planned capabilities and facilities• Ensure the NAVSEA Warfare Centers are equitably represented and aligned
within the assigned technical capabilities• Enable broad collaboration across the NAVSEA Warfare Centers in Additive
Manufacturing towards the strategic vision.
Distribution Statement A – Approved for Public ReleaseDistribution Statement A – Approved for Public Release
Additive Manufacturing at the NAVSEA Warfare Centers
Advance S&T for additive
Limited volume
manufacturing
Produce custom
fixtures/gigs
Rapid Prototyping
Fleet Support
Prototyping Chief Sees New Emphasis, Though Not Necessarily New Money By Tony Bertuca, Posted on InsideDefense.com, 7 Nov 14
“. . .‘Prototyping not necessarily leading to programs of record.‘ It gives us the chance to take risk and hopefully fail and not be hauled out onto the carpet for failing.“ - Ben Riley, Deputy Assistant Secretary of Defense for Emerging Capability and Prototyping. "
Involved in Additive Manufacturing for over a decade. . .
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WCs AM Supporting Readiness
NUWC Keyport uses:• ProMetal S15 to print sand casting
molds and cores for short lead time, low quantity, complex castings meeting original design specifications and materials.
• FDM and SLS systems support manufacturing, testing & evaluation, and repair processes with quick-turnaround thermoplastic prototypes and tools.
NSWC Panama City supports Fleet Readiness by fabricating wings and fairings for the Q-24 Underwater Mine Detection Device. Also supporting Modular Integrated Display System (MIDDS) for Full Facemasks.
NSWC Crane uses AM to validate plastic enclosure designs/ custom requirements for development of new electronics/ system designs. As an organic DoD Printed Circuit Technology capability, AM can be a bridge solution to mission critical needs.
Distribution Statement A – Approved for Public ReleaseDistribution Statement A – Approved for Public Release
AM and the Warfighter
NSWC Dahlgren (CDSA) is a part of the CNO’s Rapid Innovation Cell (CRIC) Print the Fleet project dedicated to introducing AM to the Fleet. Accomplishments:• Conducted a series of workshops, including the
Navy’s first “Maker Event”• Built non-critical parts for Fleet at shore and
shipboard• Collected user feedback to develop
requirements• Worked with NAVSUP to develop a AM data
repository (in development)• USS ESSEX (LHD-2): uPrint installation and
training of sailors to design and build non critical components for fit checks
NSWC Carderock supports the Warfighter through understanding the impact of ship motion on AM. Experiments were performed on JHSV-2 CHOCTAW COUNTY and supported the CRIC effort on USS ESSEX (LHD-2) during calm-water powering trials June 2014 (NPS Dental/ NSWCCD/NSWC Corona).•Visual/property variation in build quality
when specimens fabricated underway on CHOCTAW COUNTY and USS ESSEX.
•Ongoing work in coupled/decoupled motion and environmental effects in FY 14.
NSWC Port Hueneme, participating in the CNO’s Rapid Innovation Cell (CRIC), employs two Stratasys AM machines to print ABS plastic based parts for a myriad of purposes including• Academic aids• Tomahawk Form, Fit and
Function tests• Intra-assembly piece-part
replacement; and rapid prototyping.