Additive Manufacturing for Aerospace, Opportunities and ... and Challen… · Additive...
Transcript of Additive Manufacturing for Aerospace, Opportunities and ... and Challen… · Additive...
BOEING is a trademark of Boeing Management Company.Copyright © 2008 Boeing. All rights reserved.
Additive Manufacturing for Aerospace, Opportunities and Challenges
David Dietrich
Manufacturing Engineer
Advanced Manufacturing Research & Development
St. Louis, Missouri U.S.A.
April 15th-16th, 2008
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F/A-18 in transonic flight (Mach .8 - 1.2)
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Example of Boeing Commercial Platform
787
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Examples of Boeing Military Platforms
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Presenter’s Work History & BackgroundWork Experience
4.5 years of rapid prototyping research within Boeing-Phantom Work’s Accelerated Digital Design and Manufacturing
3.5 years of injection molding design experience
Educational Training
PhD. in Engineering Management – Missouri University of Science and Technology – (Currently Pursuing)
Master of Engineering in Manufacturing Engineering - University of Missouri – Rolla (2007)
Master of Business Administration – Maryville University of St. Louis (2004)
Bachelor of Science in Industrial Engineering Tech.– Murray State University (2000)
Industry Affiliation
Society of Manufacturing Engineers - Rapid Tooling Technology Group Chairman
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Structure of Presentation
Boeing’s Background in the field of Rapid/Direct ManufacturingPhotographic examples of rapid manufacturing applicationsThe value of direct manufacturing
Opportunities for Future Direct Manufacturing DeploymentCommercial AircraftMilitary Aircraft
Qualification & Certification RequirementsChallenges facing Direct Manufacturing
Education of the Design CommunitySystem DevelopmentMaterial EnhancementsProcess Repeatability Industry
Final Comments
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Boeing-Phantom Work’s Accelerated Digital Design and Manufacturing (ADDM)
The Phantom Works - Innovators and Integrators working across the Boeing Global Enterprise to create the future of aerospace.
The Phantom Works Mission: To be the catalyst of innovation for the Boeing Enterprise.Accelerated Digital Design and Manufacturing Team: Led by Jeff DeGrange
ADDM Mission: To find, apply, and mature rapid response technology to reduce cost, inventory, and lead time throughout product lifecycles, and to transition mature technologies to our supply chain.
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Background of Additive Manufacturing at Boeing
The Boeing Company has invested heavily into additive manufacturing technology.
77 rapid manufactured laser sintered part designs on 5 separate aircraft platforms. These aircraft platforms include both commercial aircraft and military aircraft.
Most parts are traditionally fabricated multi-part assemblies of non-critical tertiary structure designs. Part families range from clips, brackets, environmental control ducts, shroud panels.
Direct Tooling Demonstrated Additive Manufacturing
Boeing certification of equipment and material required of all suppliers of aerospace laser sintered parts
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Examples of Additive Manufactured Parts
Direct Tooling
3D CAD MODEL
FABRICATED LS DETAILS
POWER FEED DRILLING USING SLS DRILL PLATE
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Examples of Additive Manufactured Parts
Environmental Control System Ducting on aircraft
• Reduced Part Count• Flexible Design• Reduced Cost• No Tooling• Increased Cycle Time
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Example for Production Applications Multi-Functional Designs
Previous (Kevlar/Rotomold)Configuration
New (SLS) 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
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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
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Direct Manufacturing Technology will Fundamentally Change How We Think About Design, Manufacture and Support
Evaluation of Direct Nylon Components for Commercial Application
Meet Flame & Toxicity Requirements
Continue the Advancement of Direct Manufacturing of Thermoplastic and Metal Materials
Mainstream the Use for Rapid Tooling and Post-Production Support Applications
Enables the Ability to “Design Anywhere, Build Anywhere”
Incorporate Large Frame Machines, P7XX into the Supply Chain to recognize cost savings through economies of scale
Opportunities - Where Is the Technology Going?
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Opportunities - Evaluation of Direct Nylon Components for Commercial Applications
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Rapid Manufacturing Opportunities – Commercial Aircraft
Polymer Applications
Cabin Interior Paneling, Wire Bundle Clips, Airflow Diverters(NEED - Flame Retardant Polymer Certification)
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Rapid Manufacturing Opportunities – Military Aircraft
Polymer ApplicationsHigher Temperature Subsystem Zones
Exhaust Ducting, electrical shrouds, and fairings
(NEED – Higher Temperature Polymer Development)
Higher Temperature Tooling
Composite Fabrication
(NEED – Higher Temperature Polymer Development)
Secondary Structure
(NEED – Higher Modulus, % of Elongation, and Ultimate Tensile Strength Material)
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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
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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
• Process/Equipment• Materials
• Assess Maturity In Each of the Categories/ Groups/Items
• Process/Equipment• Materials
• 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
Platform Evaluation MethodologyPlatform Evaluation Methodology
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Initial Overall Technology Readiness Level (TRL) Guide
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Challenges - 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
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Challenges - System Development NeedsPlatform 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
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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
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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
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Challenges - 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”.
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Challenges - Industry
• 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
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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
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Strategic Vision for Direct Manufacturing
Capable
Education of Designers
ReliableRepeatable
Reduce Cost & Part Count
Continuous Improvement
Production Capable Direct Manufacturing System
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