Additive Manufacturing of Materials. Dr Helen Swygart Qioptiq Capability Improvement Manager

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Geoffrey Dickerson
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1 Additive Manufacturing of Materials Dr Helen Swygart Qioptiq Capability Improvement Manager

2 My Background Education (The University of Liverpool) 1 st Class Honours Degree in Mathematics MSc in Continuum Mechanics for Research and Industry PhD in Elasto-hydrodynamic lubrication theory Main Career Highlights 17 years in process engineering - worked for Corning manufacturing optical fibres - Market grew rapidly, until the bubble burst, and work was all about making more fibre as quickly as possible Have been at Qioptiq since 2002: - Previously: Project management for special projects Development and implementation of lean manufacturing onto shop floor - Currently: Capability Improvement Manager in the Technology Department developing new technologies that will be in products in the long term (5+ years)

3 Who is Qioptiq? Based in North Wales, Qioptiq design and manufacture complex and cost-effective optical modules and equipment for aerospace and defence applications. Fully space qualified components for satellite applications: radiation stable micro-sheet cover glass, optical solar reflectors and ultra thin glass

4 Extensive Experience Avimo A century of photonics expertise Qioptiq benefits from having integrated the knowledge and experience of many worldclass companies. Qioptiq today has 2000 team members working at 10 sites around the world. Currently owned by

for core products - Links with manufacture and test - Stray Light Analysis Mechanical Design - Design for

5 Core Strengths Integrated capability for the Design, Development, manufacture and Testing of advanced Electro-optical Systems Optical Design - Expertise in all wavebands from UV to LWIR - Bespoke analyses for core products - Links with manufacture and test - Stray Light Analysis Mechanical Design - Design for hostile environments - Precision Mechanisms - Complex packaging and low mass systems - Finite element analysis

Core Strengths continued Optical thin film design - Manufacturers of complex laser

systems - Expertise in plasma ion assisted evaporation (Vis/NIR/IR) - Experts in

Modelling - Embedded software & Algorithms Design for manufacture is a core strength -

6 Core Strengths continued Optical thin film design - Manufacturers of complex laser protection filters on plastic optics - World leaders in Head Up Display notch filter systems - Expertise in plasma ion assisted evaporation (Vis/NIR/IR) - Experts in highly uniform dome coatings from UV to IR Electronic Design - Servo Design - EMC Modelling - Embedded software & Algorithms Design for manufacture is a core strength - Integrated project teams - Design to cost - Manufacture optics and metal work - Bespoke test equipment

7 Products Qioptiq designs both bespoke products and off the shelf products. Customer comes to Qioptiq with a specification and we design, manufacture, build and test Or, in the case of the majority of soldier systems, Qioptiq design and manufacture a variety of weapon sights, that allow the soldier to see in various light conditions, and are available off the shelf.

8 How are technologies developed? The Business Lines deal directly with customers and develop technologies that will be in products in the short term. o Majority of this work is carried out by engineers in house o Changes are incremental The Technology Department develops technologies that will be in products in the long term (5+ years). o Some work carried out by engineers in house (particularly design work) o Majority of this work is carried out externally Access knowledge and equipment not available in house (mainly universities) o Looking for disruptive technologies step changes o When working with universities, internal project team set up consisting of: Project manager, Technology Director and an engineer Monthly conference calls and regular meetings to ensure direction of research is relevant to QUK

9 Looking Forward Industry needs reduction in S W a P - C Size Weight Power Cost

Current Technology Topics Digital holographic displays Multi-spectral systems

displays Lightweight materials & structures Computational imaging Novel imaging

Bonding dissimilar materials Optomechanics Advanced manufacturing & metrology

Additive manufacture Sensor & eye protection Coating technologies Low power &

10 Current Technology Topics Digital holographic displays Multi-spectral systems Freeform optics Infrared materials Optics in cryogenic environments Waveguide displays Lightweight materials & structures Computational imaging Novel imaging systems Optical materials Structural materials Automated manufacture & testing Bonding dissimilar materials Optomechanics Advanced manufacturing & metrology Surfaces & coatings Electronics & image processing Optical components & devices Additive manufacture Sensor & eye protection Coating technologies Low power & energy harvesting Image fusion Wireless communications GRadient INdex (GRIN) lenses Metamaterials

11 Qioptiq supplements its R&D budget with funding from external sources

12 Developed external network of technology providers

fused deposition model Makerbot Replicator 2X (desk top

13 Additive manufacturing in Qioptiq Qioptiq have two additive manufacturing machines: Dimension 1200 plastic fused deposition model Makerbot Replicator 2X (desk top machine with twin extruders, generally used with ABS filament)

14 Additive manufacturing Applications within Qioptiq Utilised predominantly in 3 areas: I. Supporting new product development 70% II. Tooling 29% III. Direct production part manufacture 1%

15 Supporting new product development a) Visual aids Models - customers, Design Reviews & programming b) Fit & ergonomics Models - Interfacing with other equipment & users c) Short lead-time / low quantity parts Functioning prototype parts e.g. eyeguards 70%

16 Why use AM to support new product development Accelerate product development Reduce time (& cost) to functioning prototype Subsequently used to de-risk production NC programming and manufacturing aid

17 Tooling Found significant utility within QUK a) Quick to manufacture Produced on site in hours / over night b) Cheap and ease of manufacture CAD file physical part, no programming/operator c) Lightweight Polymer, hollow parts 29%

18 Why use AM for Tooling? Why AM? Reduce jig cost Simplify design: eliminate assembly Lower material cost Reduce manufacturing time Printed at QUK direct from CAD file Improve user handling Reduced jig weight

19 Direct production part manufacture a) Why so low? 1) Material properties relatively poor Lower stress applications 2) Part manufacture costs generally high (currently) Exploit complexity 3) Part integrity Lack of standards Costly post-manufacture evaluation 1%

NRN PhD with Swansea University Controlled

Optical applications Supervisor: Dr Nick Lavery

Use the complexity afforded by AM to create

Produce lightweight housings that provide

20 NRN PhD with Swansea University Controlled Thermal Expansion Metamaterials for Lightweight Optical applications Supervisor: Dr Nick Lavery Student: Steven Milward What? Use the complexity afforded by AM to create structures with tailored CTEs Why? Produce lightweight housings that provide accurate lens mounts without the need for adhesives, o-rings etc. Auxetic structures AM lattices

21 Optical products Complex assemblies of: 1. Optical components Lenses, prisms 2. Mechanical structure Enclosures, mounts 3. Electronic items Switches, motors, sensors Adequate performance: 1. Maintain alignment Vibration, shock, temperature 2. Survive environment Vibration, shock, temp, humidity, fatigue

22 Structural and optical materials Optical materials Dense, hard, brittle, difficult to process Visible lens materials Schott N-BK7 IR lens materials Germanium, Silicon. With a few exceptions: CTE 6-10 x 10-6 / C Structural materials Light, rigid, cost effective Aluminium alloy: CTE 23 x 10-6 / C Titanium alloy: CTE 9 x 10-6 / C Expensive High performance polymers PEEK, GF Nylon, CTE 50 x 10-6 / C Very light, but weak

23 Tolerances Adequate performance Maintain alignment Lens decentre Lens tilt Axial shift

24 Environment Adequate performance across whole operational envelope Temperature +70 C to -40 C Subject to shock & vibration loads Mismatch in CTEs poses a significant engineering challenge! A range of lens mounting techniques available Compliant adhesives, flexures Expensive, stress components

Enable lens mounts that: Provide high precision Maintain low stresses CTE of

25 Proposed Investigation with Swansea Produce a structure with a different CTE at different locations Match CTE of structure to CTE of a lens at various locations Enable lens mounts that: Provide high precision Maintain low stresses CTE of housing matches Lens 1 CTE of housing matches Lens 2 Lens: Material 1 Lens: Material 2 Housing

26 Proposed Investigation with Swansea Enabling technology Additive manufacturing Lattice, auxetic and negative stiffness structures Not economically viable with conventional manufacturing methods

27 Title Content

28 In Summary The NRN has given Qioptiq access to knowledge and resources outside it s capability. The NRN has funded a PhD and is helping Qioptiq on it s additive manufacturing journey. The NRN has facilitated the setting up a new collaboration It is a pleasure working with Swansea University. We have a capable and intelligent student and a very supportive supervisor.

CONTROLLING THERMAL EXPANSION WITH LATTICE STRUCTURES USING LASER POWDER BED FUSION

Solid Freeform Fabrication 2017: Proceedings of the 28th Annual International Solid Freeform Fabrication Symposium An Additive Manufacturing Conference Reviewed Paper CONTROLLING THERMAL EXPANSION WITH