1. Additive Manufacturing of Multi-Scale Composites
Brian A. Czapor
300 College Park
Dayton, OH

2. Agenda Introduction to Fused Deposition Manufacturing
Ohio Third Frontier (OTF) – Advanced Materials for Additive Manufacturing Maturation
National Additive Manufacturing Innovation Institute (NAMII) – Maturation of FDM Component Manufacturing

3. Built on FDM Technology
Build Platform
FUSED DEPOSITION MODELLING

4. Background – AM Technology

5. Fortus Thermoplastics Family
Material (click blue box to view more)
Characteristic
Versatile material
Static dissipative
Biocompatible (ISO-10993)
Translucent
High Impact Strength
High Tensile Strength
FST Certification, High Mechanical
Thermal and Chemical Resistance
*Not a thermoplastic, alternate usage
ABS-M30
ABS-ESD7
ABS-M30i
ABSi
PC-ABS
Polycarbonate
PC-ISO
ULTEM 9085
PPSF/PPU
Soluble Supports*
Fortus Solutions 5

6. FDM Material Properties
Strength vs Heat Deflection
Flex Modulus vs Flex Strength
360
Flexible
ULTEM 9085
400
350
PPSF
350
340
ABS
ULTEM 9085
Heat Deflection [˚F]
300
Flexural Modulus [KSI]
330 PC
PC-ISO PC
250
320
PPSF
200
310
ABS
PC-ISO
Stiff
150
300 5 6 7 8 9 10 8 10 12 14 16 18
Tensile Strength AMB
Flexural Strength [KSI]

7. Modified Nylon FDM filament has 6. 5X modulus increase and 2
Modified Nylon FDM filament has 6.5X modulus increase and 2.5X strength increase

8. Ohio Third Frontier Program Advanced Materials for Additive Manufacturing Maturation

9. OTF - ADDITIVE MANUFACTURING
GE Aviation Engine Configurations
Lockheed/Northrop F - 35
Honda
Acura
NSX
Polymer powder
CNF/CNT
Advanced Materials for
Additive Manufacturing
Maturation
Leading Ohio’s Innovation

10. Fused Deposition Modeling
Stratasys, 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.

11. Supply Chain Developed for the OTF-IPP
Nominal 500 pound lots

12. Program Status and Schedule
Ultem 1000 selected for aerospace applications
Commercial chopped carbon fiber and CNF/CNT’s used for reinforcements
Property 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.

13. National Additive Manufacturing Innovation Institute (NAMII) Maturation of FDM Component Manufacturing

14. Distribution A: Cleared for Public Release # 88ABW-2012-5792
Project Team:
Project Lead: rp+m
SubContractors: UDRI – University of Dayton Research Institute
Northrop Grumman
Lockheed Martin
Consultants: Stratasys
GE Aviation
The Boeing Company
Distribution A: Cleared for Public Release # 88ABW

15. NAMII Project Scope Objectives Project Scope
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
Distribution A: Cleared for Public Release # 88ABW

16. Task 1 – Design Allowables

17. FDM Design Considerations

18. Sustainability Overview
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.
Distribution A: Cleared for Public Release # 88ABW

19. Workforce and Educational Outreach
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.
Distribution A: Cleared for Public Release # 88ABW

20. Outcome of NAMII Program
Members of NAMII have the rights to use the IP to generate economic development
UDRI can use the IP to help design components for industry clients
RP+M can produce the components in Ohio

21. Future Development Opportunities
Tooling for composites *(courtesy of Stratasys)

22. Sheet Metal Tooling Demonstrated Application
Hydro Form
Rubber Pad
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
Pressure Intensifiers
Punch
Blow Down
Blow Down
Male

23. Questions?
Distribution A: Cleared for Public Release # 88ABW