e-Manufacturing and UAVs
(Unmanned Aerial Vehicles)
Alex Dick - Vice President SLS Operations
A History of Plastic Laser Sintering at
Northwest UAV Propulsions Systems
and Northwest Rapid Manufacturing
May 17, 2010
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Brief Points:
• Introduction and NWUAV company history
• NWUAV – products and services
• Introducing NWRapid Manufacturing
• From prototyping to e-Manufacturing
• Future growth and applications
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About Alex:
• Mechanical Engineering degree from Grand Valley State University in Grand
Rapids, Michigan.
• 5 years at EOS as an application engineer where he was the plastics technology
expert providing training and technical support
• After meeting Chris Harris, President and Owner of Northwest UAV, Alex saw
great potential in his vision
• Leading SLS effort for last year in Oregon to help develop applications for the
UAV market and beyond
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About NWUAV and Chris:
• Company founded in 2002 by Chris Harris who has 25 years in aviation
• Previously Chris was VP of Maintenance and Engineering/Special Projects at
Evergreen International Airlines
• Projects included Boeing’s LCF, Supertanker, and NASA SOFIA
• From 1st protos to producing over 4,500 turnkey propulsion systems, 1 person
in a garage to 25+ people in about 2 years
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More About NWUAV:
• 9 total MEMS patents acquired from HP (05/2009) and PicoJet. Also licensed
patents for variable pitch propeller technology from Vari-Prop (08/2009)
• Recent AS9100 certification (07/2009), implemented ERP System (03/2009),
passed Boeing cost & pricing data audit (09/2009) and Quality Audit (02/2010)
• Software capabilities include Solidworks 2010, Altium Designer 6.0, Magics
14.0, Netfabb 4.5, and MasterCam
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Copyright Northwest UAV Propulsion Systems Inc and Northwest Rapid Manufacturing LLC
Confidential
Copyright Northwest UAV Propulsion Systems Inc and Northwest Rapid Manufacturing LLC
Confidential
Copyright Northwest UAV Propulsion Systems Inc and Northwest Rapid Manufacturing LLC
Confidential
Copyright Northwest UAV Propulsion Systems Inc and Northwest Rapid Manufacturing LLC
Products and Services Include:
• Engine design, building, and testing services (1-50 HP typical)
• Equipment includes run room, dyno (engine and propeller), and flow bench
• Variable pitch (constant speed) propeller, MEMs fuel injection for HFE engines,
and purpose built muffler
• General electromechanical services from R&D design and prototypes to
production management and assembly
• FADEC, turbo, etc?
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Forming NWRapid Manufacturing:
• Separated from NWUAV as a woman owned small business effective 12/2008
• Started by outsourcing all prototypes
 Varying quality and lead times – late and delaminating/glued
 Also volatile pricing, material availability, etc. – “out of control” process
 More critical as quantities and quality expectations increase
• Bring in house - focus on application for highest quality
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NWRapid Manufacturing Production:
• Lay foundation to bring technology in house by growing demand for parts
production business
• Purchase EOS P390 to use with PA2201 (nylon 12)
• Set parameters and control variables to make strong thin walls
• Works for 1 year – dozen thin wall geometries – thousands of parts
• P390 machine near capacity level – running 24/7
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Expanding NWRapid Manufacturing:
• Purchase P730 to increase production capacity and hire Alex Dick
• Occupying approximately 4000 sq ft for production and development
• Approach too focused to produce broad range of geometries
• Use P390 to investigate other materials and applications
• Further optimization of processes and parameters
• Grow the business in core market and beyond
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Applying e-Manufacturing:
• Start with SLS Prototype
• Small qty’s (1 to 1000s)
• High complexity (difficult to manufacture other way)
• High performance (relative to other printed parts)
• Explain limitations and/or understand end-use
• Clear and thorough communication and expectation management
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How does e-Manufacturing work:
• Understand and limit process variability
• Define process limitations (min, max, deviation, performance, and finish)
• Manage customer expectations (don’t over/under sell – straight answers)
• Connect with designers and dreamers, open-minded, give-it-a-try people
• Show what is possible, step-by-step with parts and explanation
• Continuous improvement in processes and communication
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NWRapid’s Commitment:
• Committed to quality improvement
• Revamp process for determining material
parameters
• Unfilled PA12 (PA2201) process more
reliable and versatile
• New offerings including lighter weight,
increased stiffness, investment castable,
and flexible options
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Why NWRapid’s SLS parts:
• Manufacturing is first, prototyping is second
• Prototype and production with one material/process – smooth transitions
• Dense parts with properties of base material not glue or sealant
• Glue or sealant as well as dying and/or painting okay when not Band-Aid
• Threading, inserts, metal coating – other value add post processes
• Support development, volume production – solid know-how and experience
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NWRapid’s Future Growth:
• Continue expanding portfolio - new materials and new applications
• UAV components include production ducting, shrouds, inlets, structures, flex
joints, fuel tanks, engine heads and cylinders and prototypes too.
• High quality, low cost parts work good in other markets too, already working in
consumer, medical/dental, military, and general prototyping
• Stay small and flexible with strong core know-how to grow new markets
• Grow partnership with NWUAV and grow new partnerships as well
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Questions?
Contact us for more information:
503-464-6845 or 503-437-0680
alex@nwuav.com
Also check out our websites:
www.nwuav.com and www.nwrapidmfg.com
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