Additive Manufacturing for Defense & Government MAY14, NYSE:DDD

Transcription

1 Additive Manufacturing for Defense & Government MAY14, NYSE:DDD

2 30 YEARS OF INNOVATION First 3D printed part 1983 Chuck Hull accepts National Inventors Hall of Fame Award Our founder and Chief Technology Officer, Chuck Hull, pioneered 3D printing with the invention of Stereolithography 30 years ago, and we ve been innovating ever since.

3 120 materials (polymers, ceramics, metals) WIDE 3DP TECH RANGE: Stereolithography(SLA) Selective Laser Sintering (SLS) ColorJet Printing (CJP) MultiJet Printing (MJP) Direct Metal Printing (DMP) Film Transfer Imaging (FTI) PlasticJet Printing (PJP) R&D capacity constantly innovating, to deliver new commercial products where there are/will be markets.

4 HOW COMPLEX IS THIS INDUSTRY 3DP IS NOTA MONOLITH. Manufacturability? Repeatability? Resolution? Repeatability/Resolution Low to High

5 ENGINEERED MATERIALS PERFORMANCE PARTS Conformal Structures

6 the National Additive Manufacturing Innovation Institute A once-shuttered warehouse is now a state-of-the art lab where new workers are mastering the [art of] 3D printing that has the potential to revolutionize the way we make almost everything. President Barack Obama, State of the Union, February 12, 2013

7 An Open, Layered Protocol for Powder Bed Fusion Additive Manufacturing (PBFAM) No standard protocol currently exits specifying the behavior of, monitoring, or control PBAM systems To develop and demonstrate an open, layered protocol for powder bed fusion additive manufacturing (PBFAM)

8 OPEN PARAMATERS Customizing to OEM Customers: Continuous Innovation

9 AM-Designed, Produced Heat Exchanger Demonstrate the use of laser powder bed fusion additive manufacturing (AM) processes for fabricating metallic heat exchangers for propulsion applications, to include the design, inspection, and evaluation of performance. Conceive, build, and validate a novel, highly advanced propulsion product, leveraging its resources and vast experience in heat exchanger design and laser Powder Bed Fusion Additive Manufacturing. Focuses on developing a heat exchanger that best addresses thermal fatigue, envelope optimization, pressure drop, flow distribution, and thermal performance and producing designs that feature high thermodynamic efficiency, including thin-walled highly complex structures.

10 StereolithographyProduction Series Casting patterns, molds, end-use parts and functional prototypes Develop/produce products without cost/time of CNC machining / injection molding Reduce per unit cost on low-to medium sized runs Best surface finish of any 3D printer Large, whole parts. cut time for assembly Streamline path form CAD or scan to final prod. Curing a photo-reactive resin with a UV laser

11 Selective Laser Sintering Production Series Tough End Use Parts Manufacture volumes of durable 3D mechanical properties suitable for end use and tough prototyping applications Reduce production/logistics due to no tooling No supports required with SLS Broad SLS material range Heating/fusing powdered polymer via laser

12 DIRECT METAL PRINTING: Distinctive Features 316L (1) Patented powder layering system (2) Enhanced Imaging system & software (3) Integrated hands off powder handling

13 PATENTED POWDER LAYERING SYSTEM Unlike any other system: Metal wiper lays powder bed on the build plate and a special roller compacts the metal powder to the desired layer thickness/ density on return. Parts from one batch to the next are sintered with consistencyand quality Smaller metal powder grain size when extreme detail is needed Works successfully with sphericaland non-sphericalpowder particles Works with metal and ceramics in same equipment Other systems suffer from inconsistency from one layer to the next. With this system, fully functional metal parts are directly produced.

14 Hands Off Powder Handling Avoids powder contamination Automated powder handling (closed build chamber) Good atmosphere control Safe handling of reactive materials

15 Greatest Tolerances & Repeatability High precision first time build tolerances on most dimensions Better tolerances for repeat builds that can be dialed in Unparalleled Repeatability in all 3 axes (key for manufacturing) Wall Thickness = 100 microns CoCr Ti6Al4V

16

17 Direct Metal Printing (Powder Bed AM Metal Fusion)

18 Direct Metal Printing (Powder Bed AM Metal Fusion)

19

20 Prospective Cooperative R&D Agreements (CRADAs) with U.S.-based R&D organizations Naval Air Systems Command Maintenance, Repair, Operations Reverse engineering 2017 metals qual/cert Flight Critical part(?) repeatability Naval Sea Systems Command MIL-STD-2031 ASTM E162 -Surface Flammability ASTM E662/E800 -Smoke Density/Toxicity. Metals repeatability, qual/cert

21 THANK YOU Neal Orringer, Vice President for Alliances and Partnerships NYSE:DDD