Brian A. Czapor300 College Park

Dayton, OH 45469-000brian.czapor@udri.udayton.edu

Additive Manufacturing of Multi-Scale Composites

Agenda

Introduction to Fused Deposition ManufacturingOhio Third Frontier (OTF) – Advanced Materials for Additive Manufacturing MaturationNational 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 Supportsand Use

Material(click blue box to view more)

Characteristic

Versatile material

Static dissipative

Biocompatible (ISO-10993)

Translucent

High Impact Strength

High Tensile Strength

Biocompatible (ISO-10993)

FST Certification, High Mechanical

Thermal and Chemical Resistance

*Not a thermoplastic, alternate usage

Fortus Thermoplastics

Family

Polycarbonate

PPSF/PPU

ULTEM 9085

PC-ISO

PC-ABS

ABSi

ABS-M30i

ABS-M30

Soluble Supports*

ABS-ESD7

Fortus Solutions

FDM Material Properties

PPSF

ABS

PCPC-ISO

Hea

t Def

lect

ion

[˚F]

Tensile Strength [KSI] @ AMB5 6 7 8 9 10

150

200

250

300

350

400

ULTEM 9085

PPSF

ABS

PC

PC-ISO

Flex

ural

Mod

ulus

[KS

I]8 10 12 14 16

300

310

320

330

340

350ULTEM

9085

Flexural Strength [KSI]

Flexible

Stiff

360

18

Strength vs Heat Deflection Flex Modulus vs Flex Strength

MODIFIED NYLON FDM FILAMENT HAS 6.5X MODULUS INCREASE AND 2.5X STRENGTH INCREASE

Ohio Third Frontier ProgramAdvanced Materials for Additive Manufacturing Maturation

OTF - ADDITIVE MANUFACTURING

GE Aviation Engine Configurations

Lockheed/Northrop F -35Honda Acura NSX

Polymer powder CNF/CNT

Advanced Materials for Additive Manufacturing

Maturation

Leading Ohio’s Innovation

Fused Deposition ModelingStratasys, 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

AM - FDMStratasys

Scale-up CompoundPolyOne

FabricatorRP+M

Requirements / OEMGE Aviation

HondaLockheed

Prototype CompoundUDRI

Air ForceNASA Glenn

PolymerOhioEWI

Technology & Networking

Nominal 500 pound lots

Program Status and Schedule

Ultem 1000 selected for aerospace applicationsCommercial chopped carbon fiber and CNF/CNT’s used for reinforcementsProperty 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

Distribution A: Cleared for Public Release # 88ABW-2012-5792

GE AviationLockheed MartinThe Boeing Company

Maturation of FDM Component Manufacturing

Accelerating Innovation & Increasing U.S. Manufacturing Competitiveness

Northrop Grumman

Distribution A: Cleared for Public Release # 88ABW-2012-5792

Objectives • 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

NAMII Project Scope

Task 1 – Design Allowables

Phase I(FDM Parameter Investigation)

Phase II (B-Basis Allowables Testing)

Process Parameter Exploration• 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• Strengths (tensile / compression / shear)• Moduli (tensile / compression / shear)• Bearing Strength• Tension Creep• Fatigue• Thermal (expansion / specific heat / diffusivity)• Poisson's Ratio• Density

Phase III (Supplementary Testing)

Supplementary Testing• Test hardware representative sub-elements• Bolt holes, connections, thick wall, thin wall, tooling etc.• Chemical resistance

FDM Design Considerations

Create 3D Model Print PartGreen Flag

Structural Defects

Raster +45/-45°

Repeating…

Slice 1 Slice 2 Slice 3

Raster 0°

Repeating…

Slice 1 Slice 2 Slice 3

Distribution A: Cleared for Public Release # 88ABW-2012-5792

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.

Sustainability Overview

Distribution A: Cleared for Public Release # 88ABW-2012-5792

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.

Workforce and Educational Outreach

Outcome of NAMII Program

Members of NAMII have the rights to use the IP to generate economic developmentUDRI can use the IP to help design components for industry clientsRP+M can produce the components in Ohio

Future Development Opportunities

TOOLING FOR COMPOSITES *(courtesy of Stratasys)

FDM Composite Applications

Patterns Lay Up / Cure Tools Consumable Cores Digitally Coordinated Tool Families

Trim

Too

l

Fem

ale

Tool

ing

Pat

tern

Mol

d

Mal

e La

yup

Tool

Mas

ter P

atte

rn

Nev

ada

Com

posi

te C

TE M

atch

ed T

ool

LMT

Tool

ing

Pre

preg

with

FD

M C

onsu

mab

le C

ore

Desired Part CAD Designed Tooling

Sheet Metal ToolingDemonstrated Application

• Demonstrated Applications– Hydro Forming– Rubber Pad Forming

• Demonstrated Tooling– Female, Blow Down Tools– Male Tools– Punch Tools– Pressure Intensifiers– Matched Male & Female Tools– Back Filled Tools

• Demonstrated Conditions:– 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

Hydro Form Rubber Pad

MaleBlow Down Blow Down

Pressure Intensifiers

Punch

Questions?

Distribution A: Cleared for Public Release # 88ABW-2012-5792