Additive Manufacturing of Multi-Scale Composites
Brian A. Czapor
300 College Park
Dayton, OH 45469-000
brian.czapor@udri.udayton.edu
Agenda
Introduction to Fused Deposition Manufacturing
Ohio Third Frontier (OTF) – Advanced Materials for Additive
Manufacturing Maturation
National Additive Manufacturing Innovation Institute
(NAMII) – Maturation of FDM Component Manufacturing
Built on FDM Technology
Build Platform
FUSED DEPOSITION MODELLING
Background – AM Technology
Process Model
Build
Remove Supports
and Use
Fortus Thermoplastics Family
Material
Characteristic
(click blue box to view more)
ABS-M30
Versatile material
ABS-ESD7
Static dissipative
ABS-M30i
Biocompatible (ISO-10993)
ABSi
Translucent
PC-ABS
High Impact Strength
Polycarbonate
High Tensile Strength
PC-ISO
Biocompatible (ISO-10993)
ULTEM 9085
FST Certification, High Mechanical
PPSF/PPU
Thermal and Chemical Resistance
Soluble Supports*
*Not a thermoplastic, alternate usage
Fortus Solutions
FDM Material Properties
Strength vs Heat Deflection
Flex Modulus vs Flex Strength
Flexural Modulus [KSI]
Heat Deflection [˚F]
360
400
PPSF
350
ULTEM 9085
PC
PC-ISO
300
250
200
ABS
Flexible
ULTEM
9085
350
340
ABS
330
PC
PPSF
320
310
PC-ISO
Stiff
300
150
5
6
7
8
9
10
Tensile Strength [KSI] @ AMB
8
10
12
14
16
Flexural Strength [KSI]
18
MODIFIED NYLON FDM FILAMENT HAS 6.5X MODULUS
INCREASE AND 2.5X STRENGTH INCREASE
Ohio Third Frontier Program
Advanced Materials for Additive Manufacturing Maturation
OTF - ADDITIVE MANUFACTURING
Advanced Materials for
Additive Manufacturing
Maturation
Polymer powder
CNF/CNT
Leading Ohio’s Innovation
GE Aviation Engine Configurations
Lockheed/Northrop F -35
Honda Acura NSX
Fused Deposition Modeling
Stratasys, Inc.
A KEY STRATEGIC ALLIANCE
UDRI and Stratasys have
formed a partnership designed
to accelerate development and
transition of new FDM
materials for aerospace and
automotive applications.
Supply Chain Developed for the OTF-IPP
Prototype Compound
UDRI
Technology & Networking
Air Force
NASA Glenn
Requirements / OEM
GE Aviation
Honda
Lockheed
Fabricator
RP+M
PolymerOhio
EWI
Scale-up Compound
PolyOne
AM - FDM
Stratasys
Nominal 500
pound lots
Program Status and Schedule
Ultem 1000 selected for aerospace applications
Commercial chopped carbon fiber and CNF/CNT’s
used for reinforcements
Property goals for first 500 pound scale-up batch:
tensile test, 25 ksi strength, 2 msi modulus.
FDM feedstock recently manufactured using ULTEM
1000 and CF that meets dimensional requirements.
Feedstock development is ongoing.
National Additive Manufacturing
Innovation Institute (NAMII)
Maturation of FDM Component Manufacturing
Northrop Grumman
Maturation of FDM
Component Manufacturing
Accelerating Innovation & Increasing U.S.
Manufacturing Competitiveness
Lockheed Martin
The Boeing Company
GE Aviation
Distribution A: Cleared for Public Release # 88ABW-2012-5792
NAMII Project Scope
Objectives
•
•
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Enable OEMs to productionize FDM Hardware
Raise Manufacturing Readiness Level (MRL) of
FDMTM technology for aerospace and defense
applications from level 4 to level 7
Build a platform for long-range technical and
economic developments for Additive
Manufacturing technology
Project Scope
•
•
•
•
•
Task 1: Design Allowables
Task 2: Certification Procedures
Task 3: Design Guide
Task 4: Validation
Task 5: Final Report
Distribution A: Cleared for Public Release # 88ABW-2012-5792
Task 1 – Design Allowables
Process Parameter Exploration
Phase I
(FDM Parameter Investigation)
•
•
•
•
Influence on strength DOE’s
Influence on manufacturing yield DOE’s
Influence on manufacturing rate & cost DOE’s
Sub-element scoping
Down-Select DOE Parameters
Comprehensive Materials Database
Phase II
(B-Basis Allowables Testing)
Phase III
(Supplementary Testing)
•
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•
•
•
•
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•
Strengths (tensile / compression / shear)
Moduli (tensile / compression / shear)
Bearing Strength
Tension Creep
Fatigue
Thermal (expansion / specific heat / diffusivity)
Poisson's Ratio
Density
Supplementary Testing
•
•
•
Test hardware representative sub-elements
Bolt holes, connections, thick wall, thin wall, tooling etc.
Chemical resistance
FDM Design Considerations
Create 3D Model
Green Flag
Print Part
Structural Defects
Raster +45/-45°
Raster 0°
Repeating…
Slice 1
Slice 2
Slice 3
Repeating…
Slice 1
Slice 2
Slice 3
Sustainability Overview
DOE Sustainability Goals
•
•
•
Reduced lifecycle energy cost of the FDMTM process compared to parts manufactured using the alternate
conventional manufacturing process
Energy efficiency of FDMTM manufacturing as compared to parts manufactured using the alternate
conventional manufacturing process
Environmental sustainability impacts of FDMTM manufacturing
Industry Energy Savings
•
•
•
•
•
Reductions in material use compared to existing conventional manufacturing process.
Energy savings from material substitution, including reduction in fuel burn as a result of light-weighting
structures.
Process energy of FDMTM manufacturing a part as compared to the conventional manufacturing process.
Reduction in water use as a result of using FDMTM manufacturing as compared to the conventional
manufacturing process.
Plant energy savings due to process overhaul resulting from utilization of FDMTM manufacturing compared
to the conventional manufacturing process.
Distribution A: Cleared for Public Release # 88ABW-2012-5792
Workforce and Educational Outreach
Secondary Education
•
Module presented during summer camps held at the University of Dayton: focus on introducing high school
students to careers in engineering.
Community College
•
Design Guide data & non-proprietary processes share with Sinclair Community College, Dayton, Ohio, which
operates the National Center for Manufacturing Education (NCME) for workforce training in advanced
manufacturing.
Undergraduate Education
•
University of Dayton undergraduate students will be employed to work on testing and design guide development
phases; Inclusion of material in required seminar series for undergraduate mechanical and chemical engineering
students.
Graduate Education
•
Design guidelines to be incorporated into new graduate course on AM at University of Dayton which will cover
analysis, design, and processing of structures using Additive Manufacturing.
Workforce
•
Contribution to the creation of an engineering pipeline that is prepared to meet the demands of designing
for Additive Manufacturing technologies.
Distribution A: Cleared for Public Release # 88ABW-2012-5792
Outcome of NAMII Program
Members of NAMII have the rights to use the
IP to generate economic development
UDRI can use the IP to help design
components for industry clients
RP+M can produce the components in Ohio
Future Development Opportunities
TOOLING FOR COMPOSITES *(courtesy of Stratasys)
Desired Part
CAD Designed Tooling
FDM Composite Applications
Digitally Coordinated
Tool Families
Trim Tool
LMT Tooling Prepreg with
FDM Consumable Core
Consumable Cores
Female Tooling Pattern
Male Layup Tool
Lay Up / Cure Tools
Nevada Composite CTE Matched Tool
Mold
Master Pattern
Patterns
Sheet Metal Tooling
Demonstrated Application
Hydro Form
• Demonstrated Applications
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–
Rubber Pad
Hydro Forming
Rubber Pad Forming
• Demonstrated Tooling
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Female, Blow Down Tools
Male Tools
Punch Tools
Pressure Intensifiers
Matched Male & Female Tools
Back Filled Tools
• Demonstrated Conditions:
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Range of alloys and thickness tested
Demonstrated forming pressures up to 10KSI
Variety of tools >100 cycles, some > 500 cycles
Large jointed tools have been tested
Blow Down
Blow Down
Pressure
Intensifiers
Punch
Male
Questions?
Distribution A: Cleared for Public Release # 88ABW-2012-5792