Boeing s Vision for Rapid Progress between Dream and Reality

Transcription

1 Boeing s Vision for Rapid Progress between Dream and Reality Jeffrey DeGrange Senior Manager Advanced Manufacturing Research & Development St. Louis, Missouri USA Euro-uRapid 2006 Frankfurt, Germany November 27th, 2006 BOEING is a trademark of Boeing Management Company. Filename.ppt 1

2 Digital Manufacturing Technologies Selective Laser Sintering EBM-Direct Metal Laser Projection Stereolithography Fused Deposition Modeling R.E. ATOS Scanning Laser Tracking Filename.ppt 2 SLG ppt

3 There Are Three Basic Types of Rapid Fabrication Processes on the Market Today Stereo-Lithography Apparatus (SLA) Rapid Freeze Prototyping (RFP) Wax Deposition (Thermojet) Liquid Based Photocurable Resins Water Molten Wax Ceramics Metal Semi-Crystalline Plastics Powder Based Selective Laser Sintering (SLS) ARCAM Electron Beam Melting (EBM) Laser Additive Melting (LAM) Z Corp 3D Printing Metal Sheet Solid Based Paper Amorphous Plastics Wire Laminated Object Manufacturing (LOM) Fused Deposition Modeling (FDM) Amino Local Sheet Forming (LSF) Optiform Solid Imaging Filename.ppt 3

4 Reverse Engineering ATOS Scanner Laser Tracker Reverse Engineering (RE) Data Capture RE Casting Trimming RE Damaged Tool Data Capture / Re-Mfg Filename.ppt 4 SLG ppt

5 Product Development Check-fit Articles Tie-Rod Handles All Fwd/ Aft Load Selective Laser Sintering (SLS) overnight grown articles Stereolithography (SLA) Shuttle access handle design validation Filename.ppt 5

6 Quick Response Tooling Applications SLA Router Guide Tool FDM Trim And Drill Tool SLS HSK Tool Adaptor SLA Nanoform Drill Guides Filename.ppt 6

7 Direct Manufacturing Processes Fused Deposition Modeling (FDM) rudder locks Selective Laser Sintered (SLS) Actuator Hinge Fairing Electron Beam Melt (EBM) Pivot Arm Filename.ppt 7

8 Use of Digital Information to Grow Parts Selective Laser Sintering (SLS) Uses a Computer Controlled Laser to Construct Physical Objects Directly From a 3-D Solid Model Using Powdered Materials. Process Overview 1. Create 3-D Model Base Definition (Unigraphics, CATIA, ProEngineer) 2. Electronic Delivery of the 3-D Model to SLS System D Model Sliced Into Ultra-Thin 2-D Layers and Part Program Created. 4. Laser Will Sinter Loose Powdered Material Together by Drawing and Filling the Crosssectional Cut for Each 2-D Layer. 5. Repeat Process for Each Individual Layer Until Object Is Complete. 6. Remove Objects From Bed of Powder. Filename.ppt 8

9 A Great Variety of Applicable Materials Offer SLS Design And Manufacturing Flexibility Powdered Polymers Composite Powdered Polymers Powdered Metals Many potential candidates (initial successes with Nylons, Polystyrene) Commercially produced products for other processes (i.e. plastic powder coating) Good strength, high toughness, elongation values (best of all systems) Inexpensive Loading of glass beads and other fillers improve modulus, yet reduces elongation Less shrinkage (smaller scale factors) due to stable fillers Composites can easily be dry blended and custom tailored Fillers commercially produced for other processes Steels and aluminum powders coated with a thermoplastic Post processes include sintering to burn off binder, and a bronze infiltration to obtain densification Capillary action pulls into loosely sintered pre-form Good tooling pre-form process for other processes Powdered materials processed by have a component that will melt and flow Filename.ppt 9

10 Where Is the Technology Going? Evaluation of Direct Nylon Components for Commercial Applications Meet Flame & Toxicity Requirements for Commercial Needs Continue the Advancement of Direct Manufacturing of Thermoplastic and Metal Materials Production to Additional Programs and Applications Mainstream the Use for Rapid Tooling and Post-Production Support Applications Enables the Ability to Design Anywhere, Build Anywhere Direct Manufacturing Technology will Fundamentally Change How We Think About Design, Manufacture and Support Filename.ppt 10

11 While Most Businesses Use SLS to Build Prototypes, Boeing s Applications Go Far Beyond Production Engineering Quick Response Tooling Aerospace Support Test Fit Evaluation Quick Response Tooling Quick Response Tooling Repair Support Tooling Composite Tooling Stretch Form Tooling Filename.ppt 11

12 Production On Demand Coexistence of Typical Production and Production On-Demand Out Production Parts Dynamic Supply Chaining Sample Part Scanned Results Re-Modeled Developed Build-to Package Reproduced (Prototype) Return to Agenda Filename.ppt 12

13 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 Filename.ppt 13

14 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 Filename.ppt 14

15 Development of World Wide Supply Base Revenues from rapid prototyping / rapid manufacturing industry reached $705.2M in 2004 and is growing SLS parts production for Boeing depends on collaboration with supplier networks across national borders Over (1170) SLS machines currently installed world wide High-speed and large-frame SLS 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 Filename.ppt 15

16 Key Areas- 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 Filename.ppt 16

17 System Development Needs Production Capable Operational Strategies Off-line Cool Down/Warm Up Pallet Shuttle System Approach Platform Modularity to Improve Serviceability Shaping Sub-systems Environmental Control Sub-systems Software Capabilities Process Monitoring/Data Acquisition Software Self Calibrating Capabilities Open Architecture Code (Not Necessarily Control algorithms) Filename.ppt 17

18 Certain Challenges Remain Bigger Batch Sizes Larger Part Sizes Higher Automation Part s Homogenity Logistics Flow New Part`s Designs Faster Production New Designs Have to be reflected in... Machine Design Process Technology Material Properties Quality Control & Standards Production Process & Control Parts Design & Engineering Filename.ppt 18

19 Strategic Vision for Direct Manufacturing Production Capable Direct Manufacturing System Capable Reliable Repeatable Broader Marketplace Reduce Cost & Part Count Continuous Improvement Filename.ppt 19

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