Dr. Tracy Albers President & CTO RP+M Certification of FDM Materials for Aerospace Production: Bridging the Great Divide
Certification of FDM Materials for Aerospace Production: Bridging the Great Divide Dr. Tracy Albers Rapid Prototype and Manufacturing LLC (rp+m) August 10, 2016
Certification of FDM Materials for Aerospace Production Agenda Current status of AM: Applications and Materials Qualification of Ultem 9085 for Aerospace Applications Other new materials available for FDM applications
Primary Applications of Additive Manufacturing Prototyping (presentation models, fit and assembly, visual aids, education research) still plays a majority role over functional parts. Over the last 10 years, the segment of functional parts has grown, but not as widely as one might expect.
What are the barriers?
Limitations to broad adoption: the world of polymers for AM is too small. VAT Photo polymerization (196) Binder Jetting (2) Material Extrusion (19) Material Jetting (32) Powder Bed Fusion (58) 310 polymers 19 thermoplastic materials where translatable production or injection molded solutions exist. Limited color options Limited aesthetics options
As a result translation from prototype to production doesn t happen as it should.
Let s solve the problem.
Maturation of FDM Component Manufacturing Problem Statement: Design engineers need a statistically significant data set, design guide, quality/certification procedures, and well developed supply chain in order to realize the full potential for Stratasys FDM technology in aerospace applications. Objectives: Mature Stratasys FDM technology for high temperature thermoplastic material, ULTEM 9085, on Fortus 900mc platform from TRL 4 to TRL 7. Deliverables: Mechanical test data and B-Basis allowables for Stratasys FDM ULTEM 9085, validation of sub elements of components, a design guide including certification procedures for machine, material, and facility per AS9100C. Project Benefits: Resolve critical barriers to the implementation of additively manufactured (AM) high temperature thermoplastic and foundational framework for maturing composite AM materials manufactured using Stratasys FDM
Ultem 9085 High Strength High Temperature Resistance FST Rating Strength to Weight Ratio
RESULTS 1) Material: Feedstock Analysis 2) Machine: Optimization of Build Parameters 3) Allowables dataset
Result: Understanding of filament variability Definition of acceptable tolerance of filament diameter and shape tolerance.
Result: Machine Optimization Nominal Relative Density MEAN UTS (ksi) Green Flag ZX HD, YZ HD, YX HD, ZX 14 12 10 YZ YX Modified Parameters 8 6 4 2 0 X Y Z Raster to Raster Air Gap Good surface finish / part density = 0.0024 Best surface finish / part density = 0.0025 Poor surface finish / part density = 0.0026 Green Flag Modified (-0.0024/2 AG)
Result: Bbasis Allowables dataset for Ultem Test Methods and ASTM Designation Pre-test Conditioning Environments Test Conditions Sample Build Directions Number of Samples Tested Tensile (D638) Compression (D695) Flex (D790) Bearing Strength (D953) V-Notch Shear (D5379) Tension Fatigue (D3479) Instrumented Impact (D3763) Izod Impact (D256) Tensile Creep (D2990) Fastener Pull-Through (D7332) Coefficient of Thermal Exp. Density Normal Dry ASTM D618 Condition A Saturated* -54C (-65 F) 22C (72 F) 82C (180 F) 135C (275 F) Flat (YXZ) On-Edge (YZX) Vertical (ZXY) 1461
Result: Bbasis Allowables dataset for Ultem 9085 Collected data and completed full data reduction and monte carlo simulation to generate allowable. First ever collection of data for 3D printed specimens Peer Reviewed collaborative effort
What s next? 2016/2017 Follow On Project Expansion of dataset to include 3 lots of material sourced back to resin supplier. Utilization of 3 printing locations 3 different machines Expanded sampling by 3x Currently looking for additional support by OEM s who may be interested in participating in Advisory Committee (thru America Makes)
New FDM Materials Advanced Material Case Study Program http://www.rpplusm.com/amdp-home.html
Emerging Innovations to Bridging the Tensile Modulus, Kpsi Gap 2,500 2,000 ABS-40 ABS-30 C 1,500 ABS-20 ABS-13 low sheer 1,000 ABS-10 B 500 0 A PEKK Ultem 1000 ABS PPSU PC PEEK ABS Ultem 9085 PC/ABS PA-12 Co-PI 0 5 10 15 20 25 30 Tensile Strength, Kpsi
Emerging Innovations to Bridging the Gap Material Application Target Availability 10% Carbon Fiber Filled PEI Carbon Fiber Filled Nylon 12 PEKK Tooling applications, direct part printing High strength applications, tooling and direct part printing High Heat, Chemical Resistance, direct part printing Immediate Immediate Immediate Looking for case study participants who have specific use cases where we can apply these new materials.
THANK YOU. Contact: Tracy Albers, Ph.D. President and CTO talbers@rpplusm.com www.rpplusm.com