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Manufacturing Solutions . John F Dobstetter Business Development Manager Direct Digital Manufacturing. Overview. Additive overview Tooling applications End use part applications T ooling for composites. Additive Mfg Sweet Spot. High Complexity, Low Quantity Specialty End Use Parts

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manufacturing solutions

Manufacturing Solutions

John F Dobstetter

Business Development Manager

Direct Digital Manufacturing

overview
Overview
  • Additive overview
  • Tooling applications
  • End use part applications
  • Tooling for composites
additive mfg sweet spot
Additive Mfg Sweet Spot
  • High Complexity, Low Quantity
  • Specialty End Use Parts
  • Tooling!

Additive Mfg Sweet Spot

Additive Mfg

Complexity

Conventional Mfg

Quantity

Slide Style Credit to Paul Hauwiller of GDIT

product lifecycle applications
Product Lifecycle Applications

Concept Models

Access Concept Validation

Assembly Simulation

Prototypes Models

Specialized Interface Models

Functional Test Models

Low Rate Manufacturing Tooling

Rate Manufacturing Tooling

Specialized Shop Aids

Jigs & Fixtures

End Use Parts

Repair Jigs & Fixtures

Repair Shop Aids

Repair Tooling

fdm materials
FDM Materials

Strength vs Heat Deflection

Flex Modulus vs Flex Strength

360

ULTEM 9085

350

400

PPSF

340

350

ABS

ULTEM 9085

330

300

Flexural Modulus [KSI]

Heat Deflection [˚F]

PC

PC-ISO

PC

320

250

PPSF

310

200

PC-ISO

ABS

300

150

10

18

6

8

12

14

16

5

7

8

9

10

Flexural Strength [KSI]

Tensile Strength [KSI] @ AMB

metal forming tools
Metal Forming Tools

US Naval Air Systems Command Depots

Hydro Form

Rubber Pad

Stretch Form

Tube Form

sand casting application overview
Sand Casting:Application Overview

Metal castings from sand molds

    • Many metal alloys
    • Small to very large castings
  • Pattern-based mold making
    • Matchplate, split and loose patterns
      • Gates & runners
      • Core boxes
    • Typically machined
      • Time & cost is dependent on complexity
melron corporation sand casting
MelronCorporation:Sand Casting
  • Window and door hardware
    • Non-ferrous green sand casting
    • Design inserts for maximum load and impact
  • Matchplates previously machined
    • Cost was approximately $5,000
    • Delivery lead time was 3-4 weeks
  • Now uses FDM matchplate inserts
    • FDM resists ramming forces used to pack sand
    • FDM also resists abrasion and chemicals (Top coat & mold releases)
  • Lower cost and shorter lead times
    • Cost reduced to $2,000
    • Lead time reduced to 1-1/2 weeks
mold tools
Mold Tools

High Temp Washout Core Molds

Silicone Gasket Mold

Reconfigurable Over Mold

injection molds1
Injection Molds
  • Time saving: 700-1800%
  • Cost savings:
  • 43% over aluminum
  • 72% over steel
trim drill tools
Trim & Drill Tools

Lockheed Martin Drill Tool

Coordinated Tool Family

With Drill Tool

thermoform tools
Thermoform Tools

Tool

Trials

Production

Complex Tooling

end use parts light aircraft
End Use Parts – Light Aircraft

Picture courtesy of RapidPSI

unmanned systems
Unmanned Systems

Pictures courtesy of Draganfly

Pictures courtesy of

Leptron

Pictures courtesy of

Embry-Riddle

Picture courtesy of NEO S-300 VTOL UAV Swiss UAV GmbH

coordinated tool family
Coordinated Tool Family

Part CAD Model

  • Application
    • UAV wing box
  • Benefits
    • Scaled tool size and qty to meet rate demands
    • Digitally mastered tool family
    • Concurrent tool fabrication

Trim Tool

Drill Tool

Model Based Definition

Tooling CAD Models

Lay Up Tool

Consumable Core

Co-Bond Tool

Completed Cover

Female Co-Bond Tool

Finished Part

dynamic flex test
Dynamic Flex Test

Little Margin For Over Temp

180˚C (350˚F)

120˚C (250˚F)

37%

32%

79%

fdm material application map
FDM Material Application Map
  • SR100 Soluble Cores
  • ULTEM S1 Break Out Cores
  • Caution above 150˚C/300˚F

Service

Temp

FDM

Materials

200˚C (400˚F) Max

371˚C (700˚F)

soluble cores
Soluble Cores
  • Dissolve FDM soluble core
    • WaterWorks bath solution
    • Heated tank ~ 140˚F (60˚C)
    • Agitation & circulation recommended
    • Rinse composite part
    • Duration is dependent on geometry
  • Compatible with most epoxy resins
    • WaterWorks has been demonstrated to attack some polyester resins
    • Tests to confirm resin compatibility are recommended
break out cores
Break Out Cores

ULTEM S1 CORE

Cured Part

Finished Part

  • ULTEM S1 core compromised with acetone after cure
  • ULTEM S1 becomes brittle
  • Core is broken into pieces for removal
large hybrid cores
Large Hybrid Cores
  • Mandrel Specifications
    • Hybrid mandrel
      • Aluminum main shaft
        • ~ 6’ (15.2cm) long x 9” (22.9cm) dia
      • FDM soluble core ends
        • 24” (61cm) diameter x 12” (30.5cm) tall
    • 12 lb normal load for tow winding
    • 200˚F (121˚C) Cure
  • Lessons Learned
    • Washout process is a design driver
    • Part rotation during cure evens out loads during cure cycle
hybrid break out core
Hybrid Break Out Core
  • Aluminum/ULTEM-S1 Hybrid
    • Reusable aluminum sections
    • ULTEM-S1 trapped section
    • Build time minutes
    • Minimal costs
    • Size mitigated CTE mismatch
automotive applications
Automotive Applications
  • SR-100 Soluble Tool Material
  • Produce 250°F cured composite parts
  • 80 psi pressure
  • Supports complex geometries
thin skin tooling
Thin Skin Tooling
  • Design
    • Ultem material
    • 6mm thick
    • 5hrs build time
    • Tool surfaced with epoxy
    • Vibratory polished hands off for 1 hr
  • Use
    • Released surface
    • Lay up part
    • Envelop bagging balances forces
    • Cured at 250F, 80 psi
    • Caution: geometry sensitive
larger scale tooling
Larger Scale Tooling

Boeing FDM C-channel Mandrel

Lockheed Martin Layup Tool

hybrid assemblies
Hybrid Assemblies
  • First Robotics Team #3824
    • Hardin Valley Academy
    • RoHawktics
    • Sponsored by ORNL Manufacturing Demonstration Facility (MDF)
  • Hybrid Assembly
    • FDM Fittings
    • Pultruded Rods
    • Filament winding
  • Benefits
    • Additive is great at relatively smaller more complex
    • Carbon fiber is great at long, simple, light weight, high strength structures
    • Combining provides strengths of both technologies
first robotic team 3824
First Robotic Team #3824
  • Application
    • Robot Chassis
    • Stiff/light weight
  • Solution
    • FDM light weight end pieces with critical interfaces
    • Pultruded carbon rods for spanners
    • Filament wound for bonding and strength/stiffness
  • Results
summary
Summary
  • Additive has a growing role in manufacturing
  • Stratasys provides solutions over product life cycle
  • Enabling a wide spectrum of tooling options
  • Performance materials enable end use parts
  • Real solutions for composite tooling
  • R&D efforts expand validated applications
slide32

John Dobstetter

  • Stratasys DDM Group
  • Business Development Manager
  • John.dobstetter@stratasys.com
  • 732-495-4027 o
  • 612-963-2395 c