C T M A S y m p o s i u m. Reality. WhereIdeas Become

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1 C T M A S y m p o s i u m WhereIdeas Become April 19 & 20, 2005 Tacoma, Washington Reality Kyle Morris, P.E., Naval Undersea Warfare Center Keyport, WA Dennis Reiland, General Pattern Company Blaine, MN

2 Presentation Agenda Team & RP/RM&R Background Reverse Engineering - Scanners Summary Conclusions from RE Studies Layer Based Manufacturing The Future of RM&R Questions

3 Rapid Manufacturing & Repair - Background The Industrial Members Have Been Collaborating on RP Technology Within NCMS Since 1991, Collaboratively Investing Over $21M. RM&R Evolved from the Rapid Prototyping Technology Advancement II - CTMA Program Which Ran From 2/99 through 1/03 RM&R Program Kicked Off 12/03, 2 Year Duration

4 Current Participants Honeywell FM&T NASA - Marshall Space Flight Center Naval Air Warfare Center, Weapons Division Oklahoma City Air Logistics Center General Pattern Raytheon Systems UTC Pratt & Whitney Trident Refit Facility Kings Bay Norfolk Naval Shipyard, Philadelphia Detachment Portsmouth Naval Shipyard - Forming Naval Undersea Warfare Center Division Keyport Pearl Harbor Naval Shipyard Forming Anniston Army Depot

5 Advanced Digital Fabrication or Rapid Manufacturing Definition Additive Manufacturing Processes Capable of Automatically Building Objects Directly From 3D CAD Data Without Part Specific Tooling or Manually Generated Machine Programming RP Equipment Lends Itself to This Type of Fabrication Well; These Will Be Summarized by Denny Reiland in the Next Part of This Presentation Indirect Rapid Manufacturing Tools to Generate the Computerized Product Definition of the Object to be Manufactured or Repaired In the Real World of Depot Operations, Getting 3D CAD Data is the First Challenge

6 Reverse Engineering Technology Assessment 80 Companies Product Comparison Matrix Technologies Laser Scanning Structured Light CT Scan Laser Fringe Touch Probe

7 Laser Scanning System

8 Laser Sensor Triangulation

9 Camera System

10 Touch Probe System

11 Sample Part to Scan Variety of Geometry & Features Undercuts Shrouded Areas Threads Shiny Surface

12 Comparing Scan File to Part File Scanned at Keyport LDI Scanner

13 Comparing Scan File to Part File Scanned at Keyport LDI Scanner

14 Comparing Scan File to Part File Scanned for Pratt & Whitney Perceptron Scanner

15 Comparing Scan File to Part File Scanned at Kodak Hymark Scanner

16 Comparing Scan File to Part File Scanned at HighRes Romer Arm

17 Scanning for Part Inspection Point Cloud Aligned Gold CAD Model

18 Scanning for Part Inspection

19 Reverse Engineering Objective ELECTRONIC FILE OF 3D MODEL CREATE SOLID MODEL 3D CAD MODEL (IGES) CAD SOFTWARE TECHNICAL DATA PACKAGE SCAN POINT CLOUD DATA RAPID PROTOTYPE/ CNC FABRICATED PART COMPARE TO CAD INSPECTION REPORT

20 Summary Conclusions of RE Studies Each system has its strong suits No one-size-fits-all at this point The team will continue to evaluate other scanner vendors Part Scan Data will be in a Database available to the Team and the DOD Depots as part of this project s Final Report

21 Layered Based Manufacturing Goal To build parts from Digital Data -- Any material, Any Geometry, Anywhere (on Earth or Beyond), with an economic order quantity of ONE!

22 Layered Based Manufacturing Definition: Layered Based Manufacturing (LBM) is a process where a threedimensional object is formed layer-bylayer, with a segment of each layer representing a cross section of final desired product. Adjacently formed layers are adhered to one another in pre-determined patterns to build the desired product.

23 Layered Based Manufacturing Process Output Layer Based Manufacturing Plastic Layer Sintering (SLS) Metal Laser Sintering (DMLS) SLS Uses End Use Parts Fixtures DMLS Uses End Use Parts Tools

24 Layered Based Manufacturing Metal Laser Sintering (DMLS)

25 Layered Based Manufacturing Metal Laser Sintering: How It Works? Video Clip of DMLS Processing

26 Layered Based Manufacturing Metal Laser-Sintering (DMLS) MATERIALS Currently Available DirectMetalR 20 DirectSteelR 20 DirectSteelR H20 Titanium Coming Q Chromium Cobalt Coming Q New StainlessSteelR SS17-4 Coming Q3 2005

27 Layered Based Manufacturing Metal Laser-Sintering (DMLS) Applications DirectPart prototypes for die cast parts, prototypes for sintered (powered metallurgy) parts. one-off manufacture of specialized products cost effective part production test parts, fixtures, etc

28 Layered Based Manufacturing Metal Laser Sintering (DMLS) Applications DirectTool inserts for injection molds inserts for die casting tooling vulcanization molds other tooling, e.g. sheet metal forming

29 Layered Based Manufacturing Plastic Layer Sintering (SLS)

30 Layered Based Manufacturing Plastic Laser Sintering: How It Works?

31 Layered Based Manufacturing Plastic Laser Sintering MATERIALS Currently Available SemiNylon SemiNylon GF Alumide HDNylon 12 SiliconCarbide Coming Soon

32 Layered Based Manufacturing Selective Laser Sintering (SLS) Applications DirectParts cable routing cooling ducts fasteners connectors

33 Layered Based Manufacturing Recommended For Use Pending material approval F35 J-UCAS

34 Layered Based Manufacturing Indirect Uses of LBM Investment Casting Masters Sand Foundry Pattern

35 Layered Based Manufacturing Manufacturing Costs & Savings Cost for Two Halves $2, Lower Cover $1, Upper Cover $1, Savings about $32,846 New Assembly Cost Mayport $35,000

36 Layered Based Manufacturing The Future & The Challenge

37 NCMS Advanced Digital Fabrication & Repair Program For More Information Contact: Connie Philips NCMS Program Manager (734) General Pattern

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