april 9, 2019 - better buildings initiative · 2019-05-31 · large optics diamond turning machine...

LLNL-PRES-771652This work was performed under the auspices of the U.S. Department of Energy by Lawrence Livermore National Laboratory under contract DE-AC52-07NA27344. Lawrence Livermore National Security, LLC

April 9, 2019

Lawrence Livermore National Laboratory LLNL-PRES-7716522

Manufacturing Team - 1961

Electronics cable shop - 1960

Lawrence Livermore National Laboratory LLNL-PRES-7716523

Water Jet is added to LLNL Manufacturing’s capabilities providing significant time savings over traditional saw cutting or rough machining (1990)

Laser cutting, welding and drilling provide a new manufacturing technology (late 1970’s)

Lawrence Livermore National Laboratory LLNL-PRES-7716524

Machinist prepares to rework a NOVA Beam Tube on the Gilbert Horizontal Boring Mill in the B321 Main Bay. (2002).

Approx. 42” dia. X 26’ long & 9,300 lbs

Machining the TARPOS seal surface to enable assembly (2003)

Lawrence Livermore National Laboratory LLNL-PRES-7716525

1960 - 1980 2000 2010

Diamond-turning machinesDTM-1, DTM-2, DTM-3, LODTM, PERL

Weapon componentsOptical components

Carbon-fiber composites

MicrofabricationSensors, bio systems, electrical/optical devices

1990

Precision engineeringFabrication, assembly, metrologyError budgetingDesign for manufacture

NASA mirrors

KDP finishing

LCLS x-ray phase lens

NIF ignition target

2-meter telescope mirror

EUVL camera

Diamond anvil pressure sensor Retinal prosthesis

Hydrogen fuel tank Electrostatic flywheel

Additive manufacturing

Biobriefcase

2020Munitions

Commercial diamond turning

Lawrence Livermore National Laboratory LLNL-PRES-7716526

Fabricationdiamond-turning of

2-meter mirror

AssemblyNIF ignition target

height ~1 cm

MetrologyDimensional inspection

of conical opticdiameter = 250 mm

Lawrence Livermore National Laboratory LLNL-PRES-7716527

Large Optics Diamond Turning Machine (LODTM) - World’s most accurate lathe- Calibrated accuracy of <0.1-µm over 1.5-m dia.- Numerically-controlled diamond tool- Originally designed to manufacture optics

for space-based system- Used for large, aspherical mirrors

1984 – 2009

Precitech 5-axis Diamond Turning Machine - Installed 2018- Freeform precision turning and milling- Turning surface finish <1.5 nm- Used for fabrication of NIF targets

Current

Lawrence Livermore National Laboratory LLNL-PRES-7716528

Double-Shell Ignition Targets

Fabrication: Diamond turning of aerogel + inner capsule

Assembly: Hohlraumwith inner assembly

Characterization: X-ray CT slice of gap

Gap for cryogenic geometry

Lawrence Livermore National Laboratory LLNL-PRES-7716529

An Open User facility for all Laboratory employees and outside partners

Certified Class 100 Cleanroom, Class 10 areas

Broad Semiconductor device capabilities

Dedicated medical device foundry

Lawrence Livermore National Laboratory LLNL-PRES-77165210

Pillar thermal neutron detector array

Lawrence Livermore National Laboratory LLNL-PRES-77165211

• Design, fabrication, packaging, integration and characterization of micro- and nanosystems for biologic applications

• Long-term implantable biomedical devices

• Electrode material development and characterization

• 3-D fabrication & 3-D bioprinting technologies

NIH - Brain Research Through Advancing Innovative Neural technologies (BRAIN) Initiative

Lawrence Livermore National Laboratory LLNL-PRES-77165212

Implantable Devices to cure neurological disorders:

• Depression• PTSD• Parkinson's

Artificial Retina R&D 100 & Editors Choice 2009

Neural ImplantsElectrically stimulate or record neurons and deliver or measure chemical agents

Flexible polymer electrode device to stimulate the optical

nerve with image data

Lawrence Livermore National Laboratory LLNL-PRES-77165213

Improved performance of fiber composites addresses difficult national security needs

DOD Asymmetric warfare Energy storage and generation Aircraft and Space

Lawrence Livermore National Laboratory LLNL-PRES-77165214

DesignSimulation

Optimization

SynthesisFabricationAssembly

MetrologyCharacterization

TestingSimulation

Wind pattern

Mechanical testing

Digital image correlation X-ray CT imaging

Multiscale

CNC Filament windingCustom layup

Lawrence Livermore National Laboratory LLNL-PRES-77165215

Manufacturing capability includes:• 2 CNC filament winders• 1 large CNC lathe/mill turning

machine• Multiple ovens to cure various

sizes of composite parts

Lawrence Livermore National Laboratory LLNL-PRES-77165216

Lawrence Livermore National Laboratory LLNL-PRES-77165217

Model Image correlation

Lawrence Livermore National Laboratory LLNL-PRES-77165218

Computational Engineering

Structural analysisModel orthotropic material response

Simulate composites under dynamic

conditionsMultiscale modeling

Model processing and parameters

Synthesis and Fabrication

Materials development(hybrid fiber, etc.)

Multicomponent material systems

Filament winding thermal processingMachining

Coupling to metal components

Assembly

Characterization and testing

Microstructurecharacterization

RheologyNondestructive

evaluationMechanical testing