metal am application to vita 48 - ten tech llc · vita 48.2 & redesign have similar dynamics 5%-10%...

CONFIDENTIAL/PROPRIETARY INFORMATIONThis document and the information contained herein is the property of TEN TECH LLC Engineering Services. Any reproduction, disclosure, or use thereof is prohibited except as authorized in writing by TEN TECH LLC.

Metal AM Application to VITA 48.2William VILLERS • Director of Engineering, TEN TECH LLC

EDICON USA 2017Boston, MA – 9/13/2017

https://www.tentechllc.com/https://www.tentechllc.com/http://ediconusa.com/https://www.tentechllc.com/engineering-services.html


Proposed Agenda● Introduction to TEN TECH LLC

● Company Profile● Business Organization

● Metal Additive Manufacturing● Geodetic Structures● Metal Lattice Manufacturing

● VITA 48.2 Single Board Computer● Doing Business with Us● Communication & Data Security

● Redesign of VITA 48.2 Cover● Lattice Core Design● Performance Prediction

● Closing Remarks

9/13

/201

7M

etal

AM

App

licat

ion

to V

ITA

48.

2

2

https://www.tentechllc.com/https://www.tentechllc.com/http://ediconusa.com/


INTRODUCTIONS

9/13

/201

7M

etal

AM

App

licat

ion

to V

ITA

48.

2

3

Company Profile & Business Organization

TEN TECH LLC assists Aerospace & Defense companies in designing better, saferproducts faster and at a reduced cost



William VILLERS

● CTO & Director of TEN TECH LLC● Manage Technical Aspects of the Company● Project Management & Customer Relations● Analysis Team Management

● Seasoned Aerospace & Defense Professional● MSME & ABD Doctor of Engineering, MIT France● 25 years of Industry Experience in EU & US

● Engineering & Engineering Management● CAE SME & Technical Consultant● Eurocopter, Aerospatiale, EDS

9/13

/201

7M

etal

AM

App

licat

ion

to V

ITA

48.

2

4



TEN TECH LLC Engineering Services

● Aerospace & Defense Design, Test & Analysis Consultants● ITAR-Registered Woman Owned Small Business● Cage Code Holder, Active DD-2345 DoD Certification● Offices in Los Angeles, CA and Billerica, MA

● Modeling & Simulation Subject Matter Experts● Rugged Electronics, RF & Microwave Components● Structural Dynamics, Shock & Vibration● Thermal Design & Electronics Cooling

9/13

/201

7M

etal

AM

App

licat

ion

to V

ITA

48.

2

5



Support of 20-25 A&D Programs Yearly

9/13

/201

7M

etal

AM

App

licat

ion

to V

ITA

48.

2

6



VITA 48.2 SINGLE BOARD COMPUTER

Rugged Single Board ComputerMILD-STD-810 Requirements

9/13

/201

7M

etal

AM

App

licat

ion

to V

ITA

48.

2

7



Rugged VPX Single Board Computers

● Complete Computer on Single Circuit Card● CPU, GPU, Memory, Networking, I/O● Rugged for Harsh Military Environments

● Installed in Rugged Chassis● Standard Form-Factor (ATR,…)● Integration of Multiple SBC

● Standard Mechanical Specification: VITA 48.x● Approved by ANSI in 2010● VITA 48.2 Conduction-Cooled

9/13

/201

7M

etal

AM

App

licat

ion

to V

ITA

48.

2

8



ANSI/VITA 48.2 Module

● Conduction-Cooled Module● Circuit Card Sandwiched Between Machined Aluminum Covers● Covers Act as Heatsinks & Mechanical Support

9/13

/201

7M

etal

AM

App

licat

ion

to V

ITA

48.

2

9



Environmental Requirements

● MIL-STD-810 Mechanical Specifications● Acceleration, Crash & Shock● Random & Sine-on-Random Vibration● Temperature Extremes

● Thermal Management● Components Operating Temperatures● Card Edge Temperature● Conduction to Chassis Walls

9/13

/201

7M

etal

AM

App

licat

ion

to V

ITA

48.

2

10IMAGE COURTESY OF

CM COMPUTERS



VITA 48.2 Primary Cover

● Monolithic Machined Aluminum● Main Heatsink Function● Stiffness & Chassis Interface● Metal “Islands” to

Hottest Components

9/13

/201

7M

etal

AM

App

licat

ion

to V

ITA

48.

2

11



METAL ADDITIVE MANUFACTURING

General Concept & ExamplesLattice Structure Design

9/13

/201

7M

etal

AM

App

licat

ion

to V

ITA

48.

2

12



Metal AM for Tooling & Direct Use

● AM technologies have matured significantly in recent years ● Industrial-grade materials are now being used in AM processes● Parts are being built directly for end-use and tooling applications

9/13

/201

7M

etal

AM

App

licat

ion

to V

ITA

48.

2

13



Geodetic & Lattice Structures

● Many Closely-Spaced Truss Construction ● Structural Integrity without Weight Penalty

● WWII Vickers Wellington Bomber● Achieved 40% Weight Reduction● Only feasible with assembly, at a high cost

9/13

/201

7M

etal

AM

App

licat

ion

to V

ITA

48.

2

14



Metal AM of Lattice Structures

● Very Complex Shapes Can Be Generated● With Accuracy & Repeatability● Practically No Scale Limit

9/13

/201

7M

etal

AM

App

licat

ion

to V

ITA

48.

2

15



REDESIGN OF VITA 48.2 COVER

Design & Performance PredictionPreliminary Manufacturability Analysis

9/13

/201

7M

etal

AM

App

licat

ion

to V

ITA

48.

2

16



VITA 48.2 Primary Cover Redesign

● Monolithic Aluminum Replaced with Lattice Core● Maintain External Flat Surfaces & Mounting Features● Hollow Core with Lattice Supports● Conduction Pass-through “Islands”

● 40% Mass Reduction● 2.23lb vs. 1.29lb

9/13

/201

7M

etal

AM

App

licat

ion

to V

ITA

48.

2

17



Standard VITA 48.2 External Footprint

9/13

/201

7M

etal

AM

App

licat

ion

to V

ITA

48.

2

18



Hollow Core with Lattice Structure

9/13

/201

7M

etal

AM

App

licat

ion

to V

ITA

48.

2

19



Internal Lattice & Thermal Islands

9/13

/201

7M

etal

AM

App

licat

ion

to V

ITA

48.

2

20



Vibration Performance Comparison

● Natural Frequencies & Modal Response● Stiff Enough to Prevent Dynamic Coupling with Chassis● Modal Analysis to 2000Hz

● VITA 48.2 & Redesign Have Similar Dynamics● 5%-10% Difference Between Designs

● Lattice Design Systematically Stiffer● No Spurious Modes Created by Lattice

9/13

/201

7M

etal

AM

App

licat

ion

to V

ITA

48.

2

21

VITA: 933HzLattice: 1037Hz



Thermal Performance Comparison

● Primary Heatsink Function Verification● Lattice Design Functions Similarly to VITA 48.2

● Max Temperature a few degrees higher on Lattice Design● Slight Temperature Concentration with Lattice Cover

9/13

/201

7M

etal

AM

App

licat

ion

to V

ITA

48.

2

22

VITA 48.2 Lattice Design



Preliminary Manufacturability Study

● Direct Metal Laser Sintering Process● AlSi10mg Powder● 24h Build Time

● Subtractive Manufacturing Second Pass● Surface Smoothing● Screw Holes Drilling

● Estimated Cost Below $5,000

9/13

/201

7M

etal

AM

App

licat

ion

to V

ITA

48.

2

23

https://www.tentechllc.com/https://www.tentechllc.com/http://ediconusa.com/https://youtu.be/hkhdRK__twU


Closing Remarks

● Lattice Redesign Offers Improved Performance● 40% Weight Saving over Standard Design● Higher Natural Frequencies● Comparable Thermal Performance

● Definitely Fit for Metal AM● 90% DMLS Process ● Some CNC Post Operations● Estimated 24h Production Time● Moderate Cost for Benefit

9/13

/201

7M

etal

AM

App

licat

ion

to V

ITA

48.

2

24



For More Information

● Find us online

● Website: https://ww.tentechllc.com

● Twitter: https://twitter.com/TenTechLLC

● Facebook: https://www.facebook.com/tentechllc/

● YouTube: https://www.youtube.com/user/TenTechLLC

● LinkedIn: https://www.linkedin.com/company/ten-tech-llc

9/13

/201

7M

etal

AM

App

licat

ion

to V

ITA

48.

2

25

https://www.tentechllc.com/https://www.tentechllc.com/http://ediconusa.com/https://www.tentechllc.com/contact-us.htmlhttp://www.tentechllc.com/https://twitter.com/TenTechLLChttps://www.facebook.com/tentechllc/https://www.youtube.com/user/TenTechLLChttps://www.linkedin.com/company/ten-tech-llc

Metal AM Application to VITA 48.2Proposed AgendaINTRODUCTIONSWilliam VILLERSTEN TECH LLC Engineering ServicesSupport of 20-25 A&D Programs YearlyVITA 48.2 Single Board ComputerRugged VPX Single Board ComputersANSI/VITA 48.2 ModuleEnvironmental RequirementsVITA 48.2 Primary CoverMetal Additive ManufacturingMetal AM for Tooling & Direct UseGeodetic & Lattice StructuresMetal AM of Lattice StructuresRedesign of VITA 48.2 CoverVITA 48.2 Primary Cover RedesignStandard VITA 48.2 External FootprintHollow Core with Lattice StructureInternal Lattice & Thermal IslandsVibration Performance ComparisonThermal Performance ComparisonPreliminary Manufacturability StudyClosing RemarksFor More Information

metal am application to vita 48 - ten tech llc · vita 48.2 & redesign have similar dynamics 5%-10%...

Documents