Additive Manufacturing for Aerospace, Opportunities and ... and Challen… · Additive...

BOEING is a trademark of Boeing Management Company.Copyright © 2008 Boeing. All rights reserved.

Additive Manufacturing for Aerospace, Opportunities and Challenges

David Dietrich

Manufacturing Engineer

Advanced Manufacturing Research & Development

St. Louis, Missouri U.S.A.

April 15th-16th, 2008

Additive Manufacturing for Aerospace, Opportunities and Challenges 2Copyright © 2008 Boeing. All rights reserved.

F/A-18 in transonic flight (Mach .8 - 1.2)

http://en.wikipedia.org/wiki/Image:F-18-diamondback_blast.jpg


Example of Boeing Commercial Platform

787


Examples of Boeing Military Platforms


Presenter’s Work History & BackgroundWork Experience

4.5 years of rapid prototyping research within Boeing-Phantom Work’s Accelerated Digital Design and Manufacturing

3.5 years of injection molding design experience

Educational Training

PhD. in Engineering Management – Missouri University of Science and Technology – (Currently Pursuing)

Master of Engineering in Manufacturing Engineering - University of Missouri – Rolla (2007)

Master of Business Administration – Maryville University of St. Louis (2004)

Bachelor of Science in Industrial Engineering Tech.– Murray State University (2000)

Industry Affiliation

Society of Manufacturing Engineers - Rapid Tooling Technology Group Chairman


Structure of Presentation

Boeing’s Background in the field of Rapid/Direct ManufacturingPhotographic examples of rapid manufacturing applicationsThe value of direct manufacturing

Opportunities for Future Direct Manufacturing DeploymentCommercial AircraftMilitary Aircraft

Qualification & Certification RequirementsChallenges facing Direct Manufacturing

Education of the Design CommunitySystem DevelopmentMaterial EnhancementsProcess Repeatability Industry

Final Comments


Boeing-Phantom Work’s Accelerated Digital Design and Manufacturing (ADDM)

The Phantom Works - Innovators and Integrators working across the Boeing Global Enterprise to create the future of aerospace.

The Phantom Works Mission: To be the catalyst of innovation for the Boeing Enterprise.Accelerated Digital Design and Manufacturing Team: Led by Jeff DeGrange

ADDM Mission: To find, apply, and mature rapid response technology to reduce cost, inventory, and lead time throughout product lifecycles, and to transition mature technologies to our supply chain.


Background of Additive Manufacturing at Boeing

The Boeing Company has invested heavily into additive manufacturing technology.

77 rapid manufactured laser sintered part designs on 5 separate aircraft platforms. These aircraft platforms include both commercial aircraft and military aircraft.

Most parts are traditionally fabricated multi-part assemblies of non-critical tertiary structure designs. Part families range from clips, brackets, environmental control ducts, shroud panels.

Direct Tooling Demonstrated Additive Manufacturing

Boeing certification of equipment and material required of all suppliers of aerospace laser sintered parts


Examples of Additive Manufactured Parts

Direct Tooling

3D CAD MODEL

FABRICATED LS DETAILS

POWER FEED DRILLING USING SLS DRILL PLATE


Examples of Additive Manufactured Parts

Environmental Control System Ducting on aircraft

• Reduced Part Count• Flexible Design• Reduced Cost• No Tooling• Increased Cycle Time


Example for Production Applications Multi-Functional Designs

Previous (Kevlar/Rotomold)Configuration

New (SLS) Configuration

Attach Straps Eliminated• Part Count Reduction• Quick & Easy Installation

Multiple Ducts Combined to Single-Piece Duct

Conformal Shapes Achieved and Internal Flow Features Added


Example for Production Applications The Value of Direct Manufacturing

• Engineering Design:• Direct from 3-D Model Base Definition• Design and Build Flexibility

• Production:• Eliminate non-recurring tooling costs• Lower recurring unit part costs• Faster part delivery times• Supplier flexibility• Direct Fabrication:

• 50% Cost Reduction• 67% Cycle Time Reduction at

Minimum• Product:

• Reduced part count and weight• Lower inventory and transportation

costs• Improved Life Cycle Product Costs


Direct Manufacturing Technology will Fundamentally Change How We Think About Design, Manufacture and Support

Evaluation of Direct Nylon Components for Commercial Application

Meet Flame & Toxicity Requirements

Continue the Advancement of Direct Manufacturing of Thermoplastic and Metal Materials

Mainstream the Use for Rapid Tooling and Post-Production Support Applications

Enables the Ability to “Design Anywhere, Build Anywhere”

Incorporate Large Frame Machines, P7XX into the Supply Chain to recognize cost savings through economies of scale

Opportunities - Where Is the Technology Going?


Opportunities - Evaluation of Direct Nylon Components for Commercial Applications


Rapid Manufacturing Opportunities – Commercial Aircraft

Polymer Applications

Cabin Interior Paneling, Wire Bundle Clips, Airflow Diverters(NEED - Flame Retardant Polymer Certification)


Rapid Manufacturing Opportunities – Military Aircraft

Polymer ApplicationsHigher Temperature Subsystem Zones

Exhaust Ducting, electrical shrouds, and fairings

(NEED – Higher Temperature Polymer Development)

Higher Temperature Tooling

Composite Fabrication

(NEED – Higher Temperature Polymer Development)

Secondary Structure

(NEED – Higher Modulus, % of Elongation, and Ultimate Tensile Strength Material)


Qualification & Certification Definitions

• Qualification- Focus on Controlling Variables Within Acceptable Limits- Includes Materials- Included Processing

- Also Covers Equipment Certification- Intent is Demonstrating a Stable Material and Process for Use on Applications

- Three to Five Batch Qualifications for Each Test to establish B-Basis Material Allowables

• Certification Focus is on the Application- Point Insertion- General Insertion


Step 1

Step 2

Step 3

Step 4

• Tailor AIM-C Readiness Level Guides Towards Direct Digital Manufacturing

• Process/Equipment• Materials

• Establish More Specific Questions to Translate Exit Criteria Into Relative Items


• Assess Maturity In Each of the Categories/ Groups/Items


• Establish The Specifics For Conformance Activities to Meet Maturity Exit Criteria with the Selected Technologies and Applications

• Process, Equipment, Matl’s, Structures

TRL’sxRL’s

Questionnaire

TechnologyAssessment

ConformancePlanning

Platform Evaluation MethodologyPlatform Evaluation Methodology


Initial Overall Technology Readiness Level (TRL) Guide


Challenges - Education of Design Communities

• Remove the ‘Cuffs’ of Design For Manufacturing & Assembly (DFMA)

Complexity is Ok.. Even Good!

• Propagate the Design For Function (DFF) Design Mentality

• Encourage the Adaptation of Designing Multi- Functional Parts

• Encourage sub-systems teams to work together

• Industry Service Specifications (SAE, ISO, AMS, etc.)

• Universities Must Begin to Teach the Principles of Direct Manufacturing


Challenges - System Development NeedsPlatform Up-time Must Approach 90%

Product/Process Consistency• Thermal Consistency• Dimensional Consistency

Production Capable Operational StrategiesOff-line Cool Down/Warm UpPallet Shuttle System Approach

Platform Modularity to Improve ServiceabilityShaping Sub-systemsEnvironmental Control Sub-systems

Software CapabilitiesProcess Monitoring/Data Acquisition SoftwareSelf Calibrating CapabilitiesOpen Architecture Code


Required Materials Advancements

• Incoming Product Consistency• Batch and lot traceability• Contaminant free material

• Reasonable Product Cost • The product must be available in bulk buys• Sellers must add value to the product

• Supply Chain Capable of Delivering Production Quantities• Pounds Consumed Substantially Increased with the

Number of Applications

• Improved Performance Materials• Temperature, Stiffness, Strength, Toughness, Etc.

• Base Level Standardization of Property Reporting


Required Materials Advancements• Improved Performance Materials

• Isotropic properties• Stiffness (at elevated temperatures)• Strength (at elevated temperatures) • Toughness (at low/room temperatures)• UV Resistance

• Base Level Standardization of Property Reporting• Tensile• Impact• Hardness

• Scientific Understanding of Material Characteristics and Processing Characteristics• Explanations of empirical phenomena• Develop materials performance prediction tools


Challenges - Process Repeatability

• Dimensional Accuracy and Repeatability

• Requirements for Acceptance:

• Build test article (shown left) in 9 locations within build chamber; diagonally across the x-y top, middle and bottom. All measurements between cubic facets must be within ±.007”.


Challenges - Industry

• Reliable, Prompt Maintenance• Machines cannot be down for extended periods• Selected spares stock on-site to reduce delays• Train on-site maintenance personnel on some recurring

calibrations or repairs to eliminate down time

• Reasonable Cost of Maintenance Contracts• On-site spares stock included in the maintenance

contract• Bulk buy contracts for vendors with multiple machines

• Develop Concise Troubleshooting Procedures• Eliminate the ‘Shot Gun’ approach to repairs• Reduce down time as well as cost for the OEM


Development of World Wide Supply Base

Revenues from rapid prototyping / rapid manufacturing industry reached $705.2M in 2004 and is growing

Direct manufacturing for Boeing depends on collaboration with supplier networks across national borders

Over (1170) SLS machines currently installed world wide

High-speed and large-frame machines enhance productivity and reduce part cost

Boeing standards for SLS manufacturing and quality control are well established

Certification of SLS manufacturing centers in USA, Europe, and Asia is feasible for production


Strategic Vision for Direct Manufacturing

Capable

Education of Designers

ReliableRepeatable

Reduce Cost & Part Count

Continuous Improvement

Production Capable Direct Manufacturing System

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