As a globally recognized leader in research, development and transition of technologies, the University of Dayton Research Institute (UDRI) is conducting one of three awarded America Makes MAMLS projects under the theme: Emerging Process Technology for Low Criticality Part Families. UDRI is exploring “Rapid Part Replacement” and for the purpose of this study, low criticality parts include electrical connectors, knobs, elastomeric grommets, and spacers, each of which serves a functional purpose onboard aircraft.
Both UDRI and 3D Systems also participated in Phases 1 and 2 of the MAMLS program, which help to identify the business cases for additive manufacturing for different parts, shedding light on what can and cannot be easily sourced and where using additive manufacturing makes sense.
Challenges:
Cleared for public release. Case Number: 88ABW-2018-5721 – The sustainment mission of the United States Air Force (USAF).
In legacy aircraft, parts that are out-of-production due to manufacturing obsolescence, high creation costs, low quantity requirements, unavailability of original tooling, poor documentation, or other availability-related challenges.
The sustainment mission of the United States Air Force (USAF) becomes increasingly challenging as large numbers of legacy aircraft, systems and equipment steadily age.
Solutions:
Additive manufacturing comes into play with the speed of part replacement offered by emerging technologies like Figure 4 offers an opportunity to agencies like the U.S. Air Force that can advance strategic sustainment initiatives.
3D Systems’ Figure 4 is a modular manufacturing process that uses a non-contact membrane in combination with a projector-based imaging. In contrast to toolpath-based AM technologies, Figure 4 fabricates an entire part cross-section with a single projection, retaining fine resolution, smooth surfaces, reactive production material chemistries, and fast print speeds. Figure 4 also delivers six sigma repeatability (Cpk > 2) across all Figure 4 materials, making it the most manufacturing-ready 3D printing technology available.
Benefits:
Figure 4 delivers geometric accuracy, print speed and material suitability. The prospect of performing a lasting custom repair job in a single day is highly appealing to increasing aircraft readiness and availability for same-day mission use.
Together with 3D Systems, UDRI is working through material development, characterization and post-processing protocols to align and document material performance with the requirements of aviation qualified materials. These specifications run the gamut from mechanical and environmental properties to safety standards such as fire retardancy. 3D Systems’ role is to facilitate UDRI by supplying materials for the applications under investigation in this project by either matching existing commercial photopolymers or formulating new ones.