1 rp+m

JTEG Webinar: Manufacturing for Sustainability

Tom Santelle, Director of Strategic ProgramsAugust 25, 2015

2 rp+m

Brief Overview of rp+mWorld’s First “Full Stack” AM Products and Solutions Company

• Invested in the most technologically advanced additive manufacturing systems and materials

• Providing agnostic, expert advice on all additive manufacturing technologies

• Focused on materials development and process advancement

• Emphasis on high-temperature thermoplastics and composites, refractory metals and ceramics

Bringing AM Innovation to Our Industrial Clients

Materials

Design

Processes

Software

Consulting

3 rp+m

rp+m - introduction

• rp+m is a advanced technology solutions company based on Avon Lake, OH.

• rp+m is the premier provider of customized AM products and innovative material solutions.

• rp+m was formed in 2009 out of investments from Thogus, a plastic injection molding company that specializes in the manufacture of proprietary products, custom moldings and other other plastic products.

• rp+m has been increasingly been called upon by corporations, federal, and private research institutions to develop advancements in the markets it serves.

4 rp+m

Project: AFMC Using Additive to Create Sustainability

5 rp+m

rp+m, Sustainment and the Digital ThreadRecent Additive Manufacturing Study

• USAF / AFMC two-part study to define Additive Manufacturing Information Technology (IT) Architecture Requirements

• Study 1: Identified the Data Requirements to “print” parts on-demand– Identify technical data requirements to enhance TDP’s– Design and develop 3D Printing Data Packages for selected AM platforms– Develop technology demonstrations for metal and polymer parts– Develop enhanced TDP’s to include, validated engineering drawings, models

process specs and AM machine files for deployment to depot facilities– Print “Control Parts” on DMLS and FDM platforms

• Study 2: Validate results of Study 1 and explore impacts to USAF IT Architecture

6 rp+m

Project Partners• US Air Force Material Command – Define project

requirements / scope

• DDC-IT Services – Document data model requirements

• Defense Logistics Agency – Mission Impaired Capability Awaiting Parts (MICAP)

• rp+m – Identify AM platforms, develop enhanced TDP’s, manufacture control parts, validate parts

7 rp+m

rp+m Technical Tasks and Activities

1. Collaborated with DLA / AFMC to down-selected USAF parts for study

2. Developed manufacturing / validation drawings

3. Developed CAD models and toolpath files

4. Developed print build files for FDM and DMLS platforms

5. Printed FDM and DML control parts

6. Developed process specifications for remote printing

7. Developed post processing specifications

8. Assembled a final print package for digital delivery

8 rp+m

Project Workflow Model

Stu

dy 1

9 rp+m

Phase I Part Selection Criteria

• Parts for relevant data requirements definition and validation

• Parts for non-flight, non-structural part replacement use cases

• Parts that represent both metal and polymer materials

• Analysis did not include fit-for-use analysis, design and testing

10 rp+m

Parts Selection Criteria (cont.)

• MJ-1B Bomb Lift: centering lever– Need: 48/yr Cost: $38.42

Prod Time: 277 days– Material (orig.): C-1020 steel– Material (AM): MS-1 steel

• Generator: tow latch– Need: 55/yr Cost: $72.37

Prod Time: 100 days– Material (orig.): ductile iron– Material (AM): MS-1 steel

11 rp+m

Parts Selection Criteria (cont.)

• Chart Holder: End Cap– Need: 19/yr Cost: $28.57

Prod Time: 92 days– Material (orig.): ABS M30 Black– Material (AM): ABS M30 Black

• Surrogate: Air Duct– Material (AM): ABS M30 Black

12 rp+m

Data Requirements• 3D Print Data Package

– Five components are required to print-on-demand

– Four optional components provide context and can help address unexpected problems at print-time

• 3D Print Package Data Reference Model (DRM): managed product data

– 3D print package Logical Model and attribute definitions

– 3D print package-to-Product Lifecycle Management (PLMi) DRM mapping

• Enhanced Technical Data Package (TDP) (MIL-STD-31000A): acquiring and applying 3D print package

13 rp+m

Data Requirements• 3D Print Package Data Reference Model (DRM): managed product data

– Logical Model and attribute definitions

– Product Lifecycle Management (PLMi) DRM mapping

– Technical Data Package (TDP) (MIL-STD-31000A)

AM Print Package ComponentR-requiredO-optional Description

3D Printing Process Instructions RA document file identifying the materials, consumables, build file and step-by-step instructions for fabricating an item.

Additive Manufacturing Build Instructions

R A proprietary, binary file read by a 3D Printer that contains a complete definition of a printed model, including tool paths and machine parameters necessary to fabricate an item.

OEM Documentation RMachine operating documentation from the original equipment manufacturer referenced for executing procedures such as machine setup, calibration, material loading and job execution.

Material Specification RA document that provides technical information about the feedstock material that contains information such as the material formulation, mechanical, thermal and electrical properties of the material.

CAD Validation Drawing RAn annotated drawing that provides information necessary to inspect and measure a fabricated item to validate that it is essentially identical to the original item.

CAD Manufacturing Drawing OA drawing and associated lists that provide the design, engineering, and manufacturing information necessary to enable the procurement or manufacture of an item essentially identical to the original item.

CAD Model OA 3-dimensional representation of the item describing its volume and/or surface boundary.

Build Statistics Dataset O

An ASCII text file containing basic information about an item defined in an Additive Manufacturing Build Instructions file, such as the amount and type of model and support material required to fabricate the item, the cubic volume of the item, the fabrication time, etc.

Job sheet OA tabular document used to record specific details about a print job, including machine serial number, material used, actual build time, build layout, etc.

14 rp+m

3D Print Package DRM

• 3D Print Package -PLM mapping– PLM organizes data in

Information Assets (IAs)– 3DPDP is part of the

PLI IA– Drawings/models component maps to

the Drawings-Geometry IA– Other components map to PLI

Engineering Data Lists (EDL) IA

15 rp+m

3DPDP-TDP Mapping

• 3D Print Package is a subset of the MIL-STD-31000A Technical Data Package (TDP)– Production Level (Milestone C)– TDP Elements addressed in the 3D Print Package

• Product drawings/models/associated lists

– TDP Elements not addressed in the 3D Print Package• Special Inspection Equipment drawings/models/lists • Special Tooling drawings/models/lists• Critical Manufacturing Processes• Specifications• Software documentation• Special Packaging Instructions drawings/models/lists• Quality Assurance Provisions

16 rp+m

Summary• Identified data requirements to remotely 3D Print parts

Designed and developed digital print data packages

Printed Control Parts

Delivered Additive Manufacturing Data Requirements Report

• Identified and defined the 3DPDPProvided the print “code” and instructions to print a part on demand

Identified 3DPDP data management and use instruments• Defined the 3DPDP DRM and mapped to the PLMi DRM • Mapped the 3DPDP components to the MIL-STD-31000A TDP and DI-SESS-

81000E Data Item Description

• Data requirements validation and IT Architecture analysis efforts needed to complete study objectives

17 rp+m

Contact us!

Tom Santelle, Director of Strategic Programs

tsantelle@rpplusm.com

Tracy Albers, Ph.D. President and CTO

talbers@rpplusm.com

18 rp+m

Q&A