Dd3d brian sabbart
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The document discusses the advantages of direct digital manufacturing using additive fabrication technologies, highlighting significant reductions in cost and lead times for producing composite parts and tooling. It enumerates various applications across sectors such as renewable energy, aerospace, and military, showcasing successful examples like a hybrid car and a 3D-printed surgical kit. Additionally, it features innovations in design flexibility and custom parts production, enhancing both performance and user benefit.
Dd3d brian sabbart
- 1. Direct Digital Manufacturing with Additive Fabrication Technologies May 7, 2013
- 3. Materials is what makes the difference!
- 4. Traditional Tooling Alternatives • Metal Fabrication Tooling Stretch Forming Hydro Forming • Weight savings over solid metal tooling • Self-lubricating polymers
- 5. • Large Tools • 2.3m Long Hydro Form Tool • PC Material • Methods to join parts proven Large Tool Optimized Tool 100+ Cycles 100+ Cycles Original Tool Traditional Tooling Alternatives • Metal Fabrication Tooling
- 6. End Use Parts – Renewable Energy Sandwich composites for wind turbine components • Strength to weight ratio critical • Cores increase stiffness and bending strength Commercial-grade thermoplastic Fortus generated cores • Withstand lay-up and curing process +250 F / 50 psi • Support lay-up and curing without tooling • Composite parts up to 30% lighter Result in process improvements for composite parts • Design flexibility: closed internal passages • Make changes or custom parts faster First article produced in 6 days • Reduces leadtime by 67% • Reduces costs by 52% Sandwich Composite Production Cost Cut 52% 12 days (67%) $14,000 (52%) Savings 6 days$13,000Direct Digital Manufacturing 18 days$27,000Conventional fabricating TimeCostMethod
- 8. Durable, Stable Parts Functional door handles Replacement Bumpers
- 9. Hollow Part Molds Multi-piece cores Multi-piece post bonded components FDM soluble cores
- 10. Manufacturing Urbee Urbee is a two-passenger hybrid car designed to be incredibly fuel efficient, easy to repair, safe to drive, and inexpensive to own.
- 11. End-Use Parts Current Commercial Applications • ECS Ducts • Avionics Racks • In-Flight Entertainment • Window Reveals
- 12. End Use Parts – Light Aircraft Picture courtesy of RapidPSI
- 13. Aerospace – Interior applications ULTEM 9085 Flame, Smoke, & Toxicity rated Enables commercial aerospace interior applications
- 14. End-Use Parts Future Commercial Applications Customized… • Air vent & light fixtures • Cabin interiors • Seating • Panels • Storage • Cockpit & gauge clusters
- 15. End-Use Parts Current Military/Defense Applications • Optimized wing sections • UAV’s • Wind Tunnel Models • Camera Gimbals • ECS Ducts
- 16. On Demand Additive Manufacturing of a Basic Surgical Kit DARPA Service Chiefs Fellowship Program Printed Basic Surgical Kit Uprint in mock field location connected to generator power Soldier wearing “Cut Suit” Simulated laparotomy surgery using FDM surgical tools
- 17. Design Iris van Herpen, Fashion Designer The ability to vary softness and elasticity inspired us to design a “second skin” for the body acting as armor-in-motion; in this way we were able to design not only the garment’s form but also its motion.
- 18. Emma’s Arms Nemours A Children’s Health System
- 19. Emma’s Story 3D printed “exoskeleton” lets a little girl lift her arms and play.