NAVAIR Additive Manufacturing and Digital Thread

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1 NAVAIR Additive Manufacturing and Digital Thread Ms. Liz McMichael Mr. Greg Welsh Distribution Statement A Approved for public release; distribution is unlimited NAVAIR SPR #308

Additive Manufacturing Acquisition of Systems Sustainment of Systems Dynamic Scheduling Tool Condition Based Maintenance

2 Vision 2020: The Path to Improve Readiness Anticipate and preclude risks Manage Known Risk Act on known issues Emergent requirements Legacy systems NAVAIR Way Forward End-to-End Supply Tool Vector Technical data rights Budget Harmonization Additive Manufacturing Acquisition of Systems Sustainment of Systems Dynamic Scheduling Tool Condition Based Maintenance (CBM) Readiness Forecasting Model (RCM) Predictive Analytics Model (PAM) Aviation Logistics Model (ALE) Digital Thread READINESS

NAVAIR AM Roadmap Operationalize AM across

capacity NAVAIR AM Roadmap Path Forward 1.

V-22 Flight Critical Part Digital Thread -

Fab Labs) Complete, Secure, Authoritative

3 NAVAIR AM Roadmap Operationalize AM across solution space Deliver high value AM capacity NAVAIR AM Roadmap Path Forward 1. AM for Readiness and Sustainment 2. Expanded Warfighter Capabilities 3. Enterprise Integration/Digital Workforce V-22 Flight Critical Part Digital Thread - Enterprise NAVAIR/DON AM Standards Warfighter Fabrication and Education (i.e. Fab Labs) Complete, Secure, Authoritative Data Enables Advanced Manufacturing and Digital Supply Chain Deliver AM Capabilities to Address Key Readiness Drivers

4 Ongoing Part Demos Ti-6Al-4V 15-5PH Stainless Steel AlSi10Mg Effect of build layout Alternate powder(s) Powder reuse Account for distortion New baseline material process Near net shape Aluminum castings & weldments replacements CH-53K parts H-1 parts CH-53E, T64 Engine Fuel Control Unit Parts 4

5 Metal AM for Naval Aviation Objective address surface and near surface flaws to mitigate impact to fatigue performance As-built Rough surface Near surface flaw 1. Laser parameter optimization 2. Post-build surface finishing Machined Cross section Before (red) & After (white) REM

Pilots to breathe cabin air up to an altitude of 10K feet to support continued flight operations Accelerated Production First use of

6 Distributed Digital Manufacturing = Radical Acceleration T-45 Goshawk MBU Vent Design Fleet Need: Restricted flight on the Onboard Oxygen Generation System (OBOGS) resulted in a T-45 Goshawk operational pause from April to July 2017 AM Solution: Allow Instructor and Student Pilots to breathe cabin air up to an altitude of 10K feet to support continued flight operations Accelerated Production First use of distributed additive manufacturing. From design through test and production using eight 3-D printers at six different sites to print and ship 300 valves in 15 days.

7 Scaling Additive Manufacturing into Naval Aviation Readiness Need Fielded Products Production Tracking AM Request Digital Thread Qualified Printers AM Design Solution Engineering Support 3D TDP Repository Distributed Printing Digital Technical Data

8 Scaling AM Airworthiness AM REQUESTED ASSESSMENT AIRWORTHINESS AM TECHNOLOGY MATURITY READINESS IMPACT GREEN BOX NO AIRWORTHINESS IMPACT USE OF AM ALLOWED MATERIALS AND PRINTERS AT CUSTOMER DISCRETION BLUE BOX AIRWORTHINESS IMPACT USE OF AM ALLOWED AM TECHNICAL DATA PACKAGE REQUIRED SPECIFIED MATERIALS AND PRINTERS RED BOX AM DEVELOPMENT TECHNOLOGY MATURATION STANDARDS Legend: REQUEST RECEIVED GREEN BOX NO AIRWORTHINESS IMPACT BLUE BOX AIRWORTHINESS IMPACT RED LOW AM TECHNOLOGY READINESS LEVEL/MANUFACTURING READINESS LEVEL

3D Digital Technical Data Package Digital Signature to lock

DIMENSIONS 3D PDF APPROACH IS CAD AGNOSTIC CONFIGURATION MANAGEMENT

PRINTER SETTINGS AND MATERIALS TO ENSURE QUALITY Printer settings,

9 3D Digital Technical Data Package Digital Signature to lock configuration 3D PRINTING REQUIRES A 3D MODEL CAD MODEL WITH DIMENSIONS 3D PDF APPROACH IS CAD AGNOSTIC CONFIGURATION MANAGEMENT CM APPLIES TO 95% OF NAVAL AIRCRAFT COMPONENTS MANUFACTURING CONTROL PRINTER SETTINGS AND MATERIALS TO ENSURE QUALITY Printer settings, materials data, QA attached to TDP CAD Agnostic 3D view s for critical dimensions/tolerancing

10 3D Data Management Engineering Toolset MBD 2020 and Beyond: Digital Thread Roadmap Connecting Systems Within ALE Funding Management Workflow Linkage Integrated Quality Management SIMCENTER Toolset Digital Tech data Delivery R-BOM Management Metrics Reports & Analytics Dashboard CAPA WMS TMAPS MRP MRP 2019 Platform Data Ready IOC FMC Centrally Hosted NMCI/RDT&E access PLM Solution MBD Digital Manufacturing Industrial Connectivity Process Management Workflow Linkage WMS JDRS MRP EIs TDs Analysis Data Structures Process Mapping & Workflow Configuration TMAPS SLIC JEDMICS DIFMs Maximo TPDRs Maint Plans FMECAs Source Data Work Docs QCLs 339s CDs ECPs MS SP PLMs Others STIGs Message HRA RFA CPI Etc MRP JEDMICS TMAPS DIFMS MAXIMO SLIC JDRS Etc OS File System Digital Backbone

11 Notional Digital AM Materials Data Framework Data Analytics ICME Empowered Engineering Design Manufacturing Repair Materials Modeling & Simulation Data from distributed sites, diverse AM machines/processes & test facilities Empowered Cost & Time Deployment Innovation Warfighting Capability Accelerated Qual/Cert Part Deployment

12 SUMMARY Scaling AM across Naval Aviation Digital Data Infrastructure is Key Industry and Partner Collaboration on Standards Business Process Development for Digital Data Licensing/Management 12

NAVAIR Enterprise IPT Efforts

NAVAIR Enterprise IPT Efforts Howard Owens Brent Gordon 15 April 2014 2014-320 NAVAIR Business Fiscal Year 2012 Overview ~$37.4 billion/year TACTICAL AIRCRAFT ~35,000 People (Civ/Mil/Ktr) ~8 Primary Sites