Additive Manufacturing and the Factory of the Futureammo.ncms.org/documents/Resources/Additive...

Copyright 2015 © Lockheed Martin

Additive Manufacturing and the Factory of the Future

Slade Gardner, PhD

Lockheed Martin Space Systems Company


ADDITIVE MANUFACTURING For Defense and Gov. Symposium 14 May 2015


A Globally Oriented Company Providing Security Systems, Solutions and Services to Governments Around the World

Aeronautics Integrated Systems & Global Solutions

Space Systems

Mission Systems & Training

Missiles & Fire Control


Lockheed Martin Space Systems Company: Organized to address an array of critical mission areas

Strategic and Missile Defense

Civil Space

Advanced Technology Center

Military Space

Special Programs

Commercial Space

Each Line of Business focuses on specific mission areas


Juno mission

http://www.youtube.com/watch?v=r2a42x2DDYk&feature=player_embedded


Juno mission

Goals and Overview • Understand the origin and evolution of Jupiter • Origin of solar system and planetary systems being discovered around other stars • 32 polar orbits will extensively sample Jupiter’s full range of latitudes and longitudes • Elliptical orbit swings below radiation belts to minimize radiation exposure • Global maps of the gravity, magnetic fields, and atmospheric composition • in-situ and remote sensing observations • Explore polar magnetosphere and determine what drives Jupiter’s remarkable auroras

August 5, 2011 July 4, 2016 October 9, 2013


Additive Manufacturing for Juno

Wave Guide Brackets Ti 6Al-4V Secondary structure Several parts of a few designs

Electron Beam Melting

Demonstrated 2X savings in cost Demonstrated 2X schedule improvement Confidence testing for mech properties Equivalent properties to billet machined Confidence testing for fatigue Microstructure analysis


SSC 3D Printing Advancements

• Tooling/Ground Equipment – NIRCam – Orion – Fleet Ballistic Missile (FBM) – Solar Array

• Engineering Development – A2100TR shear tie fittings – Orion gimbal – Military Support Program (MSP) fittings – Composite panel clips & inserts – Propulsion tanks

• Flight Articles – Juno secondary structure – PIRANHA camera bracket – Osiris-Rex strut (planned) – A2100TR strut (planned)

From Tooling… to Prototypes… to Flight Hardware… Significant Cycle Time and Cost Reduction


Additive Manufacturing of Large Metallic Primary Load Structures


Titanium Propellant Tank Dome

IRaD funded manufacturing demonstration • 16” scale demo manufacturing study

• Baseline tank domes are forged titanium

• Each A2100 has 5 or more tanks (10 domes)

• Laser scan of DM part ‘bulls-eye’ on deposition

• 2013 – Proof test DM tank – pressure test

Advantages

• DM Accelerates schedule

• Baseline forged dome: 12-18 Mo lead time

• DM Dome Preform was made in 3 hours

• DM Dome is ~50% cost of forged dome

• Baseline forging limitation 46” diameter

• DM Dome does not have same size limitation

Example A2100-type Propulsion System

Ti Tanks (5)

Base Stock

Direct Mfg Material


Titanium Propellant Tank

Rough Machined Ti Domes Heat Treatment and Quench Heat Treated Domes (alpha case)

Final Machined Titanium Domes

Propulsion Tank Hydrostatic Test • MEOP 450 psi – PASS

• 12 Cycles at 1.25X MEOP (565 psi) - PASS

• 50 Cycles at MEOP (450 psi) – PASS

• Burst Test 2X+ MEOP


Building the Factory of the Future


Additive Manufacturing of Polymers and Composites


Fused Deposition Modeling (FDM)

Rapid Prototyping Equipment & Method • Thermoplastic polymer – ‘3D Printing’

• Precision structures – high tolerance – feature detail

• Good mechanical properties for RP

• Fast turn around – inexpensive path to parts

Over 100 Flying Parts

Duct for X-plane UAV fuel tank

Fuel tank assembled UAV Tail and

control UAV nose cone

Inlet (R&D)

CM/SM Umbilical Mock-Up

First to flight 2004


Extension of FDM with Materials

Custom materials ready for FDM

Materials Formulation Extrusion - Resins, Fiber/Fillers, Specialty

FDM Filament Single Screw Extrusion 0.070” Diameter Profile

Analysis PP & Capillary Rheology Microscopy (SEM, AFM)

Evaluation Coupon Fab Mech & Phys Analysis

• New formulations made and tested quickly • Innovative atmosphere – design revolution • Pellets to test coupons in same day • Rapid cycle allowed development of APEX


First Large Scale Additive Polymer System

–Pointwise Composition Control - deposition of materials/properties where needed, when needed – Out-of-Chamber - localized heat source - build envelop size not limited (adaptable to gantry) – On-the-fly - blend compounding & material change-over – Tailored thermoplastic composites - broad material selection - performance attributes

Multi-hopper Polymer Drying/Vacuum Transfer System Blender/Formulator/Feeder System Robot-Polymer Extruder/CAD-CAM Controls/Deposition System

Materials: Polymers, reinforcements, and additives - dried for extrusion processing

Formulation: Automated transfer of materials and components pre-blended for extrusion processing

Deposition: Pre-blended recipe – transferred to extruder for deposition of structure

1 2 3


LM Large Additive Polymer

Rapid model or prototype Tooling fixtures, jigs, locators etc… Part simulations for manufacturing assembly Demonstrated for children and parents at USA SEF STEM event


Two Robot Additive Cluster

Additive Composite • CF/ABS process development material

• High performance materials

• Composition control

Subtractive Machining • Surface milling

• Cutout/machining

Process Monitoring • Vision system

• Thermal history

Inspection/Measurement • Laser distance probe


System Build and Check Out


Symposium Demonstrations

Defense Manufacturing Conference – San Antonio, TX – Dec 2014 DMDII Grand Opening – Goose Island, IL – May 2015 RAPID – Long Beach, CA – May 2015 Defense Manufacturing Conference – Phoenix, AZ – Dec 2015


Multi-Robot Additive Cluster

Focus: bus, substructure and mechanisms

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