Presentazione standard di PowerPoint · LEAP-1C jet engine: FAA and EASA approved. NASA Completely...

D. Stocchi

Ecor International Spa - Il Sentiero International Campus srl

L’Additive Manufacturing a supporto del settore Difesa e Sicurezza

Roma, 28/11/2019

ADDITIVE MANUFACTURING nel settore Difesa: sviluppi, prospettive e gaps

tecnologici in prospettiva industriale.

AAA Sez. Roma Due "Luigi Broglio"

ALM: an industrial vision


• “3D printing will allow aerospace manufacturers to reduce their parts production time-line from a couple of

months or weeks to a couple of weeks or days” (Greg Morris, manager of additive manufacturing and

business development, GE Aviation)

• “Our goal is to build a satellite in only 18 months instead of the traditional 36 to 48 months timeframe”

(Dennis Little, vice president of production at Lockheed Martin Space Systems)

• “AM can increase airplane engine efficiency through innovative cooling designs.” (Michael Schreyögg, chief

program officer at MTU Aero Engines AG)

• “The use of additive manufacturing technology

reduces the cost to produce components, shortens

build times and unleashes engineers to design

components that were once impossible to build

using traditional manufacturing techniques” (Julie

Van Kleeck, vice president of advanced space and

launch programs at Aerojet Rocketdyne Inc. –

ORION spacecraft)

ALM: KEY FINDINGS


Source: AEROSPACE AND DEFENSE MANUFACTURING TRENDS, Survey of Aerospace and Defense OEMs, MAY 2019, Dimensional Research-Jabil

3D PRINTING: R&D MILITARY WORK PROGRAMS


Source: Meaghan Doherty Myers: “Drones On Demand: Additive Manufacturing and the Future Battlefield “, White Paper, July 2017, europe.avascent.com

AM: weapon components


WAVE SILENCER

M203A1 40mm grenade launcher

A fully functional 1911 semiautomatic pistolSource: https://newatlas.com/3d-printing-military-feature/42384/

Source: https://3dprint.com/167567/3d-printed-grenade-launcher

Source: https://www.artstation.com/artwork/1OPnZ Source: JEREMY S. |DEC 31, 2017, Gear Review: Daniel Defense DD WAVE 3D Printed Suppressor

https://www.artstation.com/artwork/1OPnZ


Massive Ordinance Air Blast (MOAB)

FUNCTIONAL DESIGN OF THE BOMB (WALLS, THICKNESS, STRUCTURES)

Selectable effects -> “functional” behaviours on the same weapon:• small blast footprint• large blast footprint• height of burst can be controlled

3D printing: bombs more compact fitting more easily into current military aircraft, which are trending smaller than their predecessors.

Source: The Next “Mother of All Bombs” May Be Smaller, Lighter and 3D Printed

AM Manufactured 40mm Projectiles and WindscreensSource: https://www.thefirearmblog.com/blog/2017/03/22/3d-printed-grenade-and-launcher/)

AM: Weapons & Ammunition


AM & DronesMINIDRONES

• Able to work in a collective way, sharing choices and decisions.

• Threat identification• Active defence

MARBLE’S FIRST DRONE

Source: GARY MCCORMICK, “Modernizing theMilitary With Advanced ManufacturingTechnology, MANUFACTURING - JUN 20 2018

Source: http://www.stratasys.com/resources/case-studies/aerospace/aurora-flight-sciencesSource: Eugenio Santagata, Andrea Melegari, «La super-arma del futuro? Uno sciame di mini-droni dotati di intelligenza artificiale», 01/2018


AM: AeronauticsMINIDRONES



GEFuel nozzles (LEAP family engines - installed on LEAP-1A engines to Airbus). LEAP-1C jet engine: FAA and EASA approved.

NASACompletely 3D-printed rocket engine. 12 test firings successfully performed. The fuel turbopump, fuel injector, valves and several other major components of the engine were all 3D printed.

SpaceXThe Raptor system is SpaceX’s most powerful engine: over 40% 3D printed parts by mass.

BOEING“Boeing sees opportunities to use additive manufacturing to create large-scale parts and tools, and we’ve already made some progress in this area,” (Kim Smith, vice-president and general manager at Boeing Commercial Airplanes Fabrication, and Boeing’s leader on additive manufacturing)


AM: Aeronautics

MINIDRONES



GSafran Helicopter Engines Anteo-1K: incorporate 3D printed parts (including guide vanes and parts inside the combustion chamber)

Pratt & Whitney: 12 parts of an engine were created using additive manufacturing, engines that now equip Bombardier aircraft (fasteners, fuel collectors and injection nozzles 3D printed from nickel and titanium)

BAE Systems: parts used in their Tornado GR4 aircraft using additive manufacturing. Following this success, BAE Systems created more than 2.500 aircraft parts using 3D technologies in 2016, (+20% year on year).

In 2018, the Dutch Defence Helicopter Command has flown with a 3D Printed NH90 Ladder bracketfor.It’s mounted at the tail plane of the NH90 Helicopter and which is used to mount a ladder for inspection and maintenance.• Redesigned & Certified• 40% weight reduction component


AM: AeronauticsBoeing: printed 22.000 components that are used in a variety of aircrafts. Example: Environmental Control Ducting (ECD) for its new 787 aircraft.• Traditional: created from up to 20 parts (complex internal structure). • 3D printed: one piece. • RESULTS: reduces inventory, no assembly required, improved inspection and

maintenance times.

EADS: 3D–printed metal Airbus wing bracketLighter and stronger than the conventional one it could potentially replace.

F35 PROGRAM

Ferra Engineering: contract to 3D print large 2m long titanium parts for the F-35 Joint Strike Fighter, reducing machining time and materials waste.

Premium AEROTEC and Lockheed Martin: will collaborate to identify candidate parts in the F-35 aircraft that could be manufactured with additive manufacturing techniques with the target of improving efficiencies and further reducing costs as the F-35 reaches full rate production and sustainment of the operational fleet.


Leonardo is investigating ALM, to assess how such a technology might benefit the design and production of critical mechanical parts of its own electronic systems.

Mauro Varasi: «Finmeccanica nelle tecnologie di Additive Manufacturing», Foligno, 24/03/2016

AM: Aeronautics

https://www.innovationpost.it/2019/04/11/nel-futuro-dellaerospace-la-mixed-reality-e-ladditive-manufacturing/

https://www.innovationpost.it/2019/04/11/nel-futuro-dellaerospace-la-mixed-reality-e-ladditive-manufacturing/

AM for Aerospace


LauncherEngine

Source: https://www.eos.info/case_studies/additive_manufacturing_technology_otimizes_satellite_technology

Source: https://3dprint.com/220518/launcher-a-space-start-up-making-3d-printed-rocket-engines/


Production of spare parts for actually cast components, valves, brackets, housings for the next nuclear propulsion warships. First target: qualification of ALM for the construction of components in this field.

First full-scale 3D printed propeller blade demonstrator for military applications.

3D printed boat (3Dirigo):• 7,6 m long• Weight: 2268 Kg

https://3dprint.com/217390/3d-printed-military-propeller/

AM for the Navy Field

https://www.mainepublic.org/post/video-umaine-unveils-worlds-largest-3d-printer-and-patrol-boat-it-printed

http://www.difesaonline.it/news-forze-armate/mare/stampa-3d-con-tecnologia-additiva-nel-centro-sperimentazione-della-marina

https://www.mainepublic.org/post/video-umaine-unveils-worlds-largest-3d-printer-and-patrol-boat-it-printed

http://www.difesaonline.it/news-forze-armate/mare/stampa-3d-con-tecnologia-additiva-nel-centro-sperimentazione-della-marina

AM: Close to the future


Source: https://groundedcuriosity.com/meet-carl-australias-future-soldier/

https://www.defense.gouv.fr/actualites/articles/diaporama-le-felin-de-l-armee-francaise

https://www.thetimes.co.uk/article/lockheed-martin-exoskeleton-gives-soldiers-have-the-power-of-27-men-q03r0g0fx

https://groundedcuriosity.com/meet-carl-australias-future-soldier/

https://www.defense.gouv.fr/actualites/articles/diaporama-le-felin-de-l-armee-francaise

https://www.thetimes.co.uk/article/lockheed-martin-exoskeleton-gives-soldiers-have-the-power-of-27-men-q03r0g0fx

ALM for Defence at Ecor International GroupR&D developments

AM: Technologies Impact


Source: 3D Printing and the Future of Manufacturing

CSC-2016

AM: is really so expensive?

• EOIR Technology, a leading defense system design and development company, was able to manufacture mounts durable enough for use on the tanks using a 3D printer. Manufacturing costs reduced from over $100.000 per unit to under $40.000.

• In 2018, a team of U.S. Marines 3D printed a part for the F-35 stealth fighter saving $70.000 in costs for a whole new landing gear door. The component is a small part mounted on the door pressing it into the latch.

• R&D: strong impact in cost & time savings for the development of the final design.

https://www.3dnatives.com/en/marines-3d-printing-f-35-stealth-fighter-151220184/

https://www.3dnatives.com/en/marines-3d-printing-f-35-stealth-fighter-151220184/

AM: Logistics & Sustainment Mission

THE TARGET

• reverse engineer replacement parts for legacy

• aircraft that are no longer in inventory

• improve the design of existing parts before final parts are manufactured

• reduce unnecessary parts purchases

• reduce parts inventory by printing replacement parts on demand in the field

Source: A.M. Schrand “Additive Manufacturing: From Form to Function”

Source: Clare Scott, German Armed Forces Use 3D Printing to Redesign an Obsolete Part | 3DPrint.com, 10/2018


AM: Logistics and Sustainment Mission

A «DIRECT & IN FIELD» SUPPLY CHAIN

Availability of spare parts: mobile force or target practice?

ACTUAL DRAWBACKS• Extensive logistic chains connecting the

quartermaster to the front line. • Frequent target of IED’s and ambushes• Transport system stopped for breakage of

components

Portable 3D printing systems:- the unit could print parts on demand, - no waiting for the next convoy.- field print (large) spare parts.

Source: 3D opportunity in the Department of Defence, Additive manufacturing fires up, Deloitte University Press

Technology gaps & weakness concerns❑ Reliability: MATERIALS, COMPONENTS

❑ Integration with Conventional Technologies

❑ Validation and certification of AM MATERIALS, PROCESSES, PRODUCTS

❑ Criteria

❑ Methods

❑ Competences

❑ Process performance improvement ❑ - ALM variability & production rates

(dimensional accuracy & positional accuracy)

❑ - Dimensions

❑ Incremental Technical/Scientific Education Needed

❑ CND methodologies


Source:

Tech

no

logy gap

s & w

eakn

ess co

nce

rns


Olaf Diegel, Terry Wohlers, Wohlers Associates, Inc.«Additive Manufacturing: Myths, misconceptionsand untruths» , Vol. 4 No. 3 © 2018 InovarCommunications Ltd - Metal Additive Manufacturing

PART QUALITY & RELIABILITY

3D printed parts: criteria required for certification by the aviation safety regulators (Federal Aviation Administration (FAA),European Aviation Safety Agency (EASA),

1. established on the basis of experience or tests;

2. conform to approved specifications that ensure that they have the strength and other properties assumed in thedesign data;

3. take into account variable conditions in temperature, stress and humidity which may be experienced in service.


Technology gaps & weakness concerns


Technology gaps & weakness concerns


Source: “Additive Manufacturing in Aerospace and Defense”, Roland Berger study , May 2017

The way ahead for industrial success

The way ahead for industrial success

Technology development & Consolidation


LOOKING FOR INDUSTRIAL APPLICATIONS

FAVORABLE CONCERNS • Highest TRL• Validation of the results in the operation environment • TECHNICAL CONFIDENCE TOWARDS the achievements for specific classes of industrial applications

EXAMPLE: DRONESThe increment of “performance confidence” about materials and components can be structured and then transferred to biggest flight structures.

ACHIEVED: FROM FORM TO FUNCTION!!

WEAKNESS CONCERNS• Limited to specific cases • Limited “commonality” of the results• STRUCTURING OF KNOWLEDGE AND TECHNICAL DATA FROM DIFFERENT INDUSTRIAL CASES FOR THEIR

FRUIBILITY• INTEGRATION OF INDUSTRIAL R&D WITH DEFENCE STRUCTURES: SHARED VISION OF THE FUTURE

DEVELOPMENTS

AM: a strategic role in the technologies for Defence

Variables for military strategic engagement in AM

Incorporating AM has broad implications for logistics and sustainment due to its ability to rapidly field capabilities. The time and cost savings afforded by AM have the potential to revolutionize acquisitions and redefine system qualifications and certifications.

Source: A.M. Schrand “Additive Manufacturing: From Form to Function”

Using AM in ways that maximize strategic and operational agility provides decision makers with viable solutions for the multidomain challenges …

Torri Ingalsbe, “Strategic Agility Is the Future of the Air Force,” Air Force Print News Today, 30 July 2014, http://www.afmc.af.mil/news/story.asp?id=123419625.

Thank you for your attention!

mail to: [email protected]

mailto:[email protected]

Presentazione standard di PowerPoint · LEAP-1C jet engine: FAA and EASA approved. NASA Completely...

Documents

Transcript of Presentazione standard di PowerPoint · LEAP-1C jet engine: FAA and EASA approved. NASA Completely...