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Paolo Dal Cin
SVP, Operations & Supply Chain
The Aerospace & Defense industry is undergoing a transformation, as we look to leverage new technologies, implement digital tools, and increase automation to drive efficiencies and reduce cost. This transformation is changing the way we manufacture and produce everything from commercial engines to Lower Tier Air and Missile Defense Sensors. There is no question – Industry 4.0 is here, and our operational transformation to get there is underway. But to truly drive capability improvement, reduce cost and increase productivity, it will take not only operational transformation, but also a continuous focus on operational excellence.
Hear from Paolo Dal Cin, Senior Vice President of Operations & Supply Chain at Raytheon Technologies, as he shares how Raytheon Technologies is leveraging new technologies & capabilities in combination with a new operating system – CORE – to ensure the company remains a leader in the aerospace and defense industry.
Sponsored by:Grand Ballroom - Level 2
Advanced Manufacturing Tech Director
Raytheon Intelligence & Space (RIS)
Chief Executive Officer
CESMII - The Clean Energy Smart Manufacturing Innovation Institute
Shingo Institute, Utah State University
Porsche Consulting, Inc.
Senior Technical Fellow
The Boeing Company
Lean is an established and proven methodology and philosophy for achieving efficient manufacturing success through people, processes, coaching and cultural change. Industry 4.0, dubbed approximately 10 years ago, describes the world’s “fourth industrial revolution,” also termed Smart Manufacturing, initiated and driven by new and rapidly evolving technology in manufacturing, and the changes in processes, skills, organizational constructs, and human/social dynamics that accompany industrial revolutions. These two monumental topics of Lean and Industry 4.0 can at times be in conflict, synergistic, or a combination of both. FIFO can be disrupted by real-time scheduling optimization and AI; the digitization of takt boards and factory metrics, accessible remotely, can disrupt the practice of Gemba-style engagement; Kaizen related improvement outputs can be stymied by digital infrastructure. There are many more examples. But smart digital factories and automation can also enable significant efficiencies, inform decisions and processes in a Lean framework, and if done right can relieve substantial non-value add (waste) burdens from operators up through the management chain. This panel will bring together experts in the fields of Industry 4.0 and Lean to have a rich dialogue about Industry 4.0 and Lean as they evolve – sometimes in synergy, and sometimes in conflict/disruption – in the new technology laden manufacturing landscape. We are not looking for a consensus position, nor a pre-supposed answer to the relationship between Industry 4.0 and Lean – in fact much of the most interesting discussion comes from the areas of conflict/change. We appreciate and welcome your expertise and engagement in this exciting and contemporary topic.
Moderator: Kelly Dodds, Advanced Manufacturing Tech Director, Raytheon Intelligence & Space (RIS)
Grand Ballroom - Level 2
Visit the exhibits to meet suppliers, explore new technology, and ask questions of the experts.Halls A-C
How to Automate Successful Manual Finishing Steps by Increasing Process Safety, Quality and Reduce Health Issues
Manual operation is still very common in the industry when it comes to material removal. Often those manufacturing steps are hated but critical steps in manufactures process flow. Just for the simple fact that they are labor-intensive, health-endangering, or repetitive work steps – such as sanding or grinding – which are demanding on the employees. Nevertheless, often those critical tasks define repeatability and quality of your products. The automation of these work steps gives you the significant competitive advantage needed in a global market. Labor shortage in general or the simple fact that there is nothing as a finishing school, propels the demand of installing robots for those 3D (dirty, dusty, dangerous) jobs. No matter which fact or multiple reasons force manufactures to automate their applications, the right path is critical.
From knowing the limitations of technologies, to defining the scope, choosing a robot, the right tool, process to which abrasive or media change to use puts companies in every size for substantial burdens. Mistakes in this process can result in high costs to a non-functional cell. In form of best practice cases, we will demonstrate those challenging robotics applications by using different robotics technologies and compare the suitability on different industry tasks. The focus will be on the applications on aerospace parts, like composite or carbon parts – small parts to complete fuselages on substrate, primer, clear coat, or paint removal as well as deburring and turbine blade operations.
John D. Russell, D.Sc., FSME
Chief, Structures Technology Branch
Air Force Research Laboratory
Head of Product Development
Solvay Composite Materials
Technical Director, Composites Manufacturing Technology Center
Advanced Technology International
The need for automation in the manufacture of aerospace composite components will be increasing over the next decade if forecasts for a coming wave of new commercial and military aircraft as well as Urban Air Mobility platforms stress the current composites industrial base. A key variable that is often overlooked on automation is the material. It is taken for granted that we can use current aerospace composite materials for automation solutions. This panel will explore materials needs for future aerospace components and discuss what needs to happen to optimize them for automation, will maintaining their properties.
Moderator: Dr. John Russell D.Sc., Chief, Structures Technology Branch, Air Force Research Laboratory
Satyandra Gupta, PhD, FSME
University of Southern California - Los Angeles, CA
Surface finishing represents a large portion of manufacturing operations. Sanding is a widely used surface finishing process during manufacturing of parts made from metal and composite. Sanding is an ergonomically challenging operation. Traditionally robots are used only on mass production applications. The manual programming of robots is economically not viable in high-mix applications; therefore, sanding has remained a manual operation. The advent of human-safe robots is enabling robots to collaborate with humans on ergonomically challenging tasks and amplify human productivity. This enables robots to perform a large fraction of sanding operation and only requires humans to perform the final touch-ups. The availability of 3D vision and force sensors enables robots to operate without custom fixtures and accommodate part and fixture variability. These recent advances in robotics make it possible for robots to be used in high-mix sanding applications. This presentation will describe artificial intelligence technology to enable robotic assistants to program themselves from the high-level task descriptions and utilize sensor data to adapt the programs to deliver efficient and safe operational performance. The robotic sanding solution ensures quality consistency, increases productivity, and enables scalability in production for the manufacturers.
Director, Business Development - Aerospace
IPG Photonics Corporation
In manufacturing, maintenance, repair, and overhaul (MRO) of aerospace components thorough cleaning is usually required. Examples include for example cleaning before coating, surface polishing or roughening, cleaning before any joining operations such as welding or brazing. MRO often requires coating stripping. Three main technologies are currently used: abrasive grit blasting, abrasive water jetting and chemical cleaning/stripping. All these technologies produce negative impact on environment and health. On top of that, they are slow and expensive. The intent of this talk is to present laser cleaning solution that intended to replace these legacy technologies. Laser cleaning/ablation is known in the industry, but the use is limited due limited access to correct laser sources and a concern of part damaging by laser heat.
This presentation will demonstrate successful applications of laser cleaning to different cleaning/ablation tasks that improve productivity and repeatability (as laser cleaning can be fully automated), direct cost savings and part performance improvements (quality).
President & CEO
EVP, Business Development, Marketing & Sales
A&D Production Operations Evangelist, SAP Aerospace and Defense Industry Business Unit
School of Polymer Science and Engineering, University of Southern Mississippi
Head of Product Development
Solvay Composite Materials
The application of Industry 4.0 technologies and concepts in Aerospace manufacturing has taken off in numerous directions, as the industry’s leading OEMs and suppliers seek to leverage the massive range of opportunities it presents.
The smart factory concept represents a real and revolutionary transformation that is already happening and marks the future of industrial manufacturing. A smart factory implements technologies such as robotics and automation, cloud computing, big data, data analytics artificial intelligence (AI), and the internet of things (IoT), hence it can operate largely autonomously with an ongoing everlasting ability to optimize, a lot more than humans can do on their own.
During this panel, each of the panelists will share the experience his organization or company gained with regards to advanced technologies related to industry 4.0 and smart factories, how they see the progress various manufacturers made recently, and in what technologies manufacturers invest today in order to remain competitive. In addition, how the panelists propose to measure the benefits and ROI related to these technologies.
Moderator: Avner Ben-Bassat, President & CEO, PlataineGrand Ballroom - Level 2
Comparison of Additively Manufactured Printed Conductors Verses Traditional Wire Bonding in RF Circuitry
RF Senior Engineer
Under the Radar Affordability program sponsored by OSD, ACI worked on a prototype design and development of a broadband passive limiter circuit test coupon, which compares the performance of gold wire bonds against 3-D, printed additively manufactured silver conductors. The Optomec Aerosol Jet printer (AJ300) was utilized in developing a relatively new process which can achieve fine pitch and high-resolution printing of Nano-materials. The Aerosol Jet is a non-contact, mask-less printing process for printing fine pitch structures with the capability to process various inks (Conducting and non-conducting) containing Nano-particles. This presentation will show the selection procedure which includes validation of the equipment, processes, materials, and dielectric support structures necessary for printing conductive RF connections in high reliability military circuitry. Additionally, the test results between the performances of traditional wire bonding (15 samples) verses additively manufactured printed RF conductors (15 samples) will be demonstrated over a wide range of frequencies. The presentation will also cover the challenges for Additive Manufacturing (AM) which includes bridging the air gap between substrate and die, and the sintering process required to produce the conductive traces needed to achieve electrical equivalence to wire bonding.
Aerospace Program Manager
All aerospace companies continue to struggle to successfully implement automation. The product design, manufacturing requirements, product certifications, and product complexity make automation significantly more difficult that industries like automotive. There is many new technologies and capabilities that are not commonly known throughout aerospace that can solve many of the difficulties of the past. This presentation will show many different real examples of automation applicable to aerospace processes and provide updates on new developments that further ease the implementation of advanced automation for some of aerospace’s most difficult processes. The presentation will also show the many benefits of collaborative robotics and collaborative applications and how a collaborative solution can be properly implemented for a successful manufacturing process. In addition to showing real solutions and new technology developments, this presentation will describe the key project concepts common to all successful automation projects and describe how to avoid the common mistakes that cause automation to fail.
Mueller Additive Manufacturing Solutions
Topology Optimization and Generative Design have received a great deal of press about their ability to greatly reduce the weight of components without sacrificing performance. To date, however, there are few examples where such designs have been implemented, primarily because of the difficulty and cost of manufacturing optimized components in production.
This case study covers a foundry owner’s effort to use topology optimization to redesign an investment cast instrument housing. His customer informed him that the aircraft component that he had been casting for several years was a candidate for light-weighting and that he would likely lose the order. He decided to be proactive and look for an alternative casting design that would not only meet the weight reduction goals of the manufacturer but would result in fuel savings greater than the increased cost of manufacture. Although it presented significant manufacturing challenges, the resulting design not only exceeded the weight reduction objectives of the customer, but the expected fuel savings far exceeded the increased cost of manufacture.
Regional Head of Advanced Robotic Applications
The manufacturing of large, heavy parts, sometimes in small batches, has always been challenging, even with automation. Over the last decade, however, new, more flexible automation technology has been developed to enable more companies to automate their production. One such solution is the mobile robot, platforms with or without robots that are capable of transporting, processing, and measuring heavy, big parts. It is now possible to precisely maneuver mobile platforms, carrying up to 100 tons of payload. These mobile robots make it possible to process or check the quality of large parts without the need for big, complex installations.
The presentation will show how mobile platforms and robots can be used to increase the flexibility of automation projects in the manufacturing environment. Several application examples will be presented to illustrate the implementation of these technologies with focus on large and heavy part production.
Eliana Fu, PhD
Industry Manager: Aerospace & Medical
Additive Manufacturing, known colloquially as 3D Printing, is now an established method of manufacturing, is real and not a gimmick. We are currently in a new space race, which is being led by commercial tech start-ups. These companies are small, nimble-acting and forward-thinking, refuse to do things the old way and embrace the new. For these companies and more, Additive Manufacturing is the key to unlocking access to space. As we seek to push the boundaries of human space flight, the challenge for space launch providers and the associated supply chain, is to provide greater access to space by improving products, deploying new materials, simplifying designs, decreasing part count, reducing errors and driving smarter and leaner operations. Additive Manufacturing is also an enabling technology for automation, machine learning and AI. From combustion devices for rocket engine propulsion to wire arc additive manufacturing of domes, barrels and fuel tanks, the technology is providing real solutions to space exploration problems. 3D Printing in microgravity and off-planet is another aspect of Additive Manufacturing which is making science fiction become science fact. As we recommence exploring our solar system, Additive Manufacturing is the key to unlocking access to space.
WR-ALC Robotics and Automation Subject Matter Expert, Air Force
Warner Robins Air Logistics Complex
The use of specialized, custom, “bolted down” equipment, designed for specific workloads, monopolizes valuable production floor space and hampers our ability to be agile. The utilization of commercial off-the-shelf (COTS) industrial robots, mobilized and armed with COTS supporting hardware, artificial intelligence/machine learning software, model-based manufacturing capabilities, and simplified operator interfaces is a huge step toward “Creating an Agile Factory Floor”. This technology enables organizations to respond quickly to the ever-changing warfighter needs. This presentation will describe and highlight the lessons learned, successes achieved, and potential future applications through the examples of the current installation and operation of two mobile robots deployed at the Warner Robins Air Logistics Complex. These robotic systems are designed to be reconfigurable for future workloads, weapon systems, applications, capabilities, and even duty stations with little or no additional investment. This novel approach improves readiness with robotic systems that can be maintained and serviced organically, while merging the features and capabilities typically only found in one-off, custom equipment, with the agility and flexibility required to meet the on-going needs of the warfighter. The mobile nature of these systems can cut installation cost by 80% or more while shrinking installation schedules from months to days or even hours.
Dan Braley, CAM-T
Associate Technical Fellow – Additive Manufacturing Technical Focal & Initiatives Lead
Boeing Global Services
As aerospace and defense assets continue to age and exceed the lives they were expected to be in service, the need for spares and repairs continues to increase. Advanced manufacturing concepts such as Additive Manufacturing (AM) are required in order to reduce spare part lead times and the need for costly, long lead tooling. This presentation will walk through the AM technologies that are prevalent within the aerospace and defense industry for spares and repairs applications. Two technologies that will be discussed include hybrid AM and cold spray. A discussion around the advancements seen to date in AM for sustainment as well as what hurdles are still yet to be overcome will ensue.
Collaborative robots are the fastest growing segment of the robotics industry and will continue to grow at the highest rate for the foreseeable future. Most cobot applications are limited to teaching the robot to move to a dozen points or less and turn something on or off. Cobots are capable of much more but require more sophistication than teaching it a few points. How this can be accomplished to make automation of dull, dirty and repetitive tasks affordable for OEMs, upper tier suppliers and small and medium size manufacturers is a topic of interest.
Chief Strategy Officer
The keynote speech will discuss the key manufacturing approaches and technology to enable Virgin Orbit to go from a vacant factory to successful launch and a 20 launch vehicle per year production facility within four years. The discussion will include Virgin Orbit’s usage of key manufacturing tools and equipment including the following: Artificial Intelligence; Composite tape wrapped Liner-less Composite Propellant tanks; Additive and subtractive manufacturing; automated Spray-on-foam Insulation; and Ultrasound Composite inspection. Additionally, Virgin Orbit’s philosophy on Factory Flow; Automation versus Hand Lay-up; Vertical Integration; and impact of Rate, learning curve effect and design on cost and inherent system reliability will be discussed. Finally, the success of the last launch and the attributes of the air-launch system will be provided.Grand Ballroom - Level 2
Dean Bartles, PhD, FSME, FASME
Chief Executive Officer & President
MTDG - Manufacturing Technology Deployment Group
Glenn Daehn, PhD
Mars G. Fontana Professor of Metallurgical Engineering
The Ohio State University
Vice Provost IT, Office of Advanced Research Computing
University of California, Los Angeles
Director of Technical Operations
Babak Raeisinia, Ph.D.
Co-founder and CTO
Machina Labs, INC.
A discussion on tools and practices. Where are we going?
Moderator: Dean Bartles, PhD, FSME, FASME, Chief Executive Officer & President, MTDG – Manufacturing Technology Deployment GroupGrand Ballroom - Level 2
Visit the exhibits to meet suppliers, explore new technology, and ask questions of the experts.Halls A-C
We present a brief overview of existing parallel kinematic robots (PKMs) and look into how workspace singularities and joint limits have reduced their applicability to small workspaces and niched applications.
This is compared with the industry’s demand to use robots for both additive and subtractive manufacturing and how existing accuracy and rigidity have shown not to be sufficient for good part quality.
The fundamental differences between traditional robots and PKMs are explained in the context of the new potentials they bring. The Cognibotics parallel kinematic robot concept based on eight links is explained, and we show how this solution overcomes both the limitations of existing PKMs and the shortcomings of traditional industrial robots. We explain how the solution uses 6 links, arranged to optimize the cartesian workspace size and rigidity, combined with two additional links to provide a large orientational workspace for 5 and 6 axis processes with a need for speed, accuracy, and rigidity.
We also present an example of a prototype robot installation based on this concept which provides great properties for a hybrid manufacturing solution, capable of both additive and subtractive manufacturing.
- Explain how parallel kinematic robots can achieve higher performance than traditional robots.
- Understand performance limitations of articulated industrial robots on today’s market.
- Identify new manufacturing processes which can be improved with the use of parallel kinematic robots.
Technical Sales & Business Development Manager
In the past it was easy to determine a part was done by ATL or AFP. Easy parts were mainly done by Automatic Tape Laying ATL, complex ones were typically done by Automatic Fiber Placement AFP. Today, it is needed to determine the right business case for each part based on scrap ratio, productivity, and feasibility. This presentation will define 2-3 business cases examples justifying the final machine selection architecture and technology, focusing on latest, MTorres Tape Laying technology called V3 ATL head. Due to the increase in speed, and lower acquisition price of ATL vs AFP, the new head is bringing new life into the ATL world.
Todd J. Hammer, Sr.
President & CEO
Belotti America, Inc.
To remain competitive, manufacturers must implement the most cost-effective methods of changing over the tooling in their NC machines, but often times the smaller shops don’t have the depth of experience that large job shops benefit from. This Case Study presentation is intended to level the playing field.
In recent years there has been a continual advancement in thermoplastic parts. Improvements have come from many different sources, working together to produce, test and improve the whole process of production. The thermoplastic prepreg, machine builders, and process steps have been continually improved to bring about final parts that can be used in aviation.
In this presentation we will specifically look at the automated layup process of high-temperature thermoplastic prepreg, on complex shaped parts. The problems that arise in this process are numerous, but there has been continual advancement in improving the process parameters, machine hardware and methods of control. We have been performing many real layup tests on coupons, small scale parts, and mid-size prototype parts, using PPS, PAEK, PEKK, and PEEK material from most world-known prepreg suppliers. From these results, we discuss the improvements in various process control methods utilized to get much better final parts than it has been expected from the past and how Tier 1 suppliers are using these results for final material selection. Finally, we present briefly how to transition some of those learnings to tool-less manufacturing of TPCs and discuss some limits, capabilities, and future opportunities in expanding this novel approach to new markets for TPC manufacturing.
Matthew M. Robinson
ROS-Industrial Program Manager
Southwest Research Institute
Southwest Research Institute
The A5 (Advanced Automation for Agile Aerospace Applications) program is a four-year effort, sponsored by the United States Air Force Research Lab, to enable agile and flexible automation for critical Air Force sustainment needs. Led by a development team from the National Center for Defense Manufacturing and Machining, Southwest Research Institute, and the Boeing Company, this program seeks to change the paradigm of traditional robotics by leveraging the advanced capabilities of ROS. Traditional automation solutions for aerospace tend to be purpose-built machines, often dedicated to a specific aircraft or component, that require large capital investment and operating expenses. This effort pushes toward a future in which the automation solutions can easily adapt to new tasks and environments and use sensor data to close the loop on process variability. To that end, the team has developed an open-source robotics platform for rapidly deploying automation solutions for a variety of processes, including sanding and non-destructive inspection. The goal of this presentation is to illustrate how we applied and developed ROS open-source software tools to construct this automation platform. The presentation will describe the core capabilities of the system, highlight the many challenges encountered during design, and describe the solutions we implemented in deploying the prototype system for both these initial processes and inspection and extending the software to other platforms and applications.
- Understanding the capability of contemporary open-source tools for advanced capability development.
- Understand the feasibility for a potential advanced application in their domain.
- Scope out a potential project that leverages these advanced capabilities.
Director, Fiber Placement
There are at least three significant cost driving problems with the lamination of modern composite aerospace components. These problems are exaggerated for high production rate systems but affect all forms of automated fiber placement style lamination. 1) The utilization of AFP lamination equipment is structurally stuck at about 25-30%. This is true even though the systems have improved immensely in both reliability and performance. 2) The input costs are very high, for example carbon fiber prepreg or thermoplastic. 3) Autoclaves are huge and expensive and Airframers seem to dislike them a great deal.
This presentation will address the problems associated with item (1) poor utilization of AFP equipment and the steps we have taken to increase it by a factor of at least 4. We will explain how the quality systems in place structurally hold our AFP equipment to such low utilization and explain how AFP4.0 address these factors. AFP4.0’s main thrust maintains the safeguards that ensure acceptable laminations but automate the manual interventions that currently happen between each ply which are the cause of this low utilization.
Leslie Jay Cohen, PhD
You cannot increase production and capture price down with rate up unless the people and processes are aligned. This presentation will presents case studies of how this was accomplished.Grand Ballroom - Level 2
Co-Founder and CEO
FormAlloy Technologies, Inc
Jeffrey Riemann, MS
FormAlloy Technologies, Inc.
Metal Additive Manufacturing processes such as Directed Energy Deposition (DED) can produce complex geometries with incredible benefits for applications, but there are challenges between concept design and producing a part. To create quality, repeatable parts, in-process monitoring can be utilized to both collect data and control the build process. The data collected can help determine the point of failure initiation, and with implemented control in place, self-correction is possible during the build process. With Directed Energy Deposition, various monitoring and control modes are available to reduce parameter development times, improve build quality, and limit operator input during a build. Among these control modes are melt pool size and temperature, powder flow, laser power, and geometric monitoring and control. These control modes not only significantly reduce the process parameter development cycle, but also result in a higher quality build to include density and material properties.
Composite Automation, LLC
Introduce the history of Fiber Patch Placement with the goal of creating context for the progression of the technology. Thereafter, I will show the various applications where Fiber Patch Placement has had a significant impact in meeting or exceeding manufacturing metrics for success as well as new applications. I will then inform the group about the new system available for Manufacturing Research and Development at the National Institute of Aviation Research’s ATLAS lab in Wichita, KS.
Chemical Post-Processing Advantages for High Temperature Metal Alloys on Additive Manufactured Parts
Director Business Development
Tech Met, Inc.
The use of additively manufactured high temperature components offer many benefits including cost reduction, better performance and lower risk, however, the parts created using these processes are often left with trapped or partially processed powder and, rough surfaces, heat scale and other imperfections which cause difficulty in FPI and Blue light inspection.
Chemical milling and surface post-processing for high temperature additively manufactured, 3D printed metal parts is available today on a wide variety of alloys including all printed titanium alloys, aluminum alloys (including A205) and high temperature corrosion resistant alloys (Inconel 625, Inconel 718, Haynes 188, and cobalt chrome).
Chemical post-processing improves the surface finish of parts and provides a methodology to enable product realization and meet design specifications. The finishing process can enhance a part’s surface characteristics, geometric accuracy, aesthetics, mechanical properties, and facilitate FPI and blue light inspection. Some typical applications for chemical surface treatment operations are:
- Significant improvement of fatigue performance
- Removal of unwanted surface crystalline morphologies
- Surface preparation for dye penetrants or other inspection processes
- External and Internal support structure removal
This process has been successfully used to provide a method to remove partially sintered or loose powder particles on internal and external surfaces, decrease overall surface roughness of the printed component with an average of 60-70% reduction between incoming and post processed parts, and reduces scale or oxidation layers to promote FPI interpretability.
Yourri-Samuel Dessureault, PhD
Manufacturing Research and Development Engineer
This presentation will demonstrate a method of producing aerospace quality structural members by using common equipment and materials, which together create a step molding process that emulates pultrusion. By introducing a step press technique, the short coming that hot pressing has of requiring a large mold to produce the part in a single step can be eliminated. Polyphenylene sulfide commingled carbon fiber braiding was pressed in a specially designed tool to validate the viability of the work. The resulting parts were of several common structural member geometries including straight and curved t-section and hat channels. Additionally, large beaded panel was proven to be manufacturable. Together, a demonstration of a simple yet effective thermoplastic composite processing method that could be implemented in the aerospace industry without the need for advanced technology was established.
Shawn Kelly, Ph.D
Applications and Technology Americas
Cost per part is the largest issue gating the adoption of Metal AM for serial production. Quality material can only be welded so fast before the properties start to drop off. Factors such as machine build volume, number of lasers, powder layer thickness, and part orientation can play a significant role in reducing the price of building a part. Optimizing the current generation of machines to produce material faster is one of the biggest industry drivers today. Metal AM gets faster every year, applications that used to not make sense may now be reaching a cost break point where additive could now be considered. If Metal AM is to be taken seriously as an alternate form of manufacturing not just complex geometry but simpler parts for supply chain reduction the cost per part needs to be significantly lower. We will address these topics and share practical considerations to optimize machine productivity and reduce production costs.
Composites Product Manager
Unless someone is involved in manufacturing, when a person hears the word robot, they most likely picture a machine out of a sci-fi film that resembles a human. The term robot probably also draws up the fear in most of us that robots will someday make our jobs obsolete. In fact, robots already exist in many manufacturing facets to improve quality, efficiency, and profitability. This presentation seeks to explain the different composites processes that currently take advantage of the unique skillset robots offer, the pros and cons of selecting robotics, the future projections of robots, and why we should welcome them with open arms instead of dreading their arrival in the world of automated composites.
Bhaskar Dutta, PhD
Farhad Ghadamli, CAM-F
Lead Additive Manufacturing Engineer
Additive Manufacturing (AM) is emerging as a mainstream manufacturing technology, and demand for large part manufacturing is getting stronger. Direct Metal Deposition (DMD) is a DED technology based on laser and powder metal application using a closed-loop-feedback control system. This presentation will give an overview of the DMD technology highlighting its capability to scale up to large size parts. The focus will be DM3D’s new multi-nozzle DMD technology capable of printing parts up to 10ft in diameter, 10ft in height and 5000 lbs. in weight. The multi-nozzle DMD technology doubles the part throughput with a further possibility of quadrupling it. Other challenges such as residual stress and distortion related to large scale AM will be discussed in detail. Simulation approaches to mitigate such challenges will be demonstrated through example parts. Finally, a case study involving 3D printing of a very large size real-world part, namely NASA’s RS 25 engine nozzle will be discussed. Benefits and risks of 3D printing such parts that are more than 9ft in height and weighs more than 3500Lbs will be highlighted.
Large format composites manufacturing suffers from high costs of retooling. As automated layup reaches new industries, market demand for equipment targeting decades-long production runs becomes less common. Automated Fiber Placement (AFP) and its deployment in manufacturing systems must respond with innovative equipment configurations and flexible processes.
Concurrently, large-format additive manufacturing (LFAM) is experiencing a generational change. Experts are emerging while machine builders and material suppliers are maturing. A demanding and concentrated user group with unique process challenges requires focused yet flexible solutions.
This presentation highlights application concepts born from the acceleration of LFAM and the paradigm shift in production AFP. Case studies, market segments and emerging technology will be discussed in depth while focusing on the hybrid machine tool as an enabling design principle.
Ingersoll Machine Tools (Rockford, IL) brings to Additive Manufacturing an over 125-year history of engineering innovation in large scale machine tools for the aerospace, transportation, energy and defense industries. Today Ingersoll designs and builds advanced subtractive and additive manufacturing machines for a wide variety of complex processes and motion control applications.
Enjoy complimentary drinks, meet with exhibitors, and connect with attendees and speakers.
Jamil Baghdachi, PhD
Innovative Technical Systems Corp.
Aerospace and military assets require high performance, reliable coatings and long-term durability. The objective of this interactive and applied workshop is to offer a sound assessment of the latest developments in materials, application methods, and process selection. The workshop will focus on material properties, both coatings and substrates, their application, and design of a high performance and environmentally compliant coating operations.
In order to meet aggressive demands for modernization of technologies used across the border, US military as well as their suppliers must undergo significant technology advancements and future Department of Defense (DoD) workforce must be equipped with advanced hybrid, scalable, flexible, and extensible tools to adapt to growing complexities. Manufacturing sector is considered the backbone of economic development and prosperity of the nation and Wichita, Kansas is the most manufacturing-specialized metropolitan area (32% of employment in manufacturing) in the United States. Because of the established eco-system around manufacturing innovation as well as available infrastructure and resources, the proposed effort will focus on a manufacturing-centric educational program that encompasses various science, technology, engineering, and mathematics (STEM) disciplines throughout product life cycle from conceptual design to fleet sustainment. Digital engineering for all aspects of manufacturing (design optimizations, analysis, virtual reality visualization, machine programming, and high-fidelity inspections) and robotics for automation are two of the key focus areas built into the proposed program for appealing to the next generation of engineers and scientists for STEM-related disciplines through industry-scale research programs and partnerships with DoD/industry. Proposed program aims to develop a multi-disciplinary manufacturing environment and an engineering education program in the following three areas:
- Future: create a pipeline of “industry-ready” future engineers for advanced manufacturing processes
- Present: work with industry solving current manufacturing problems providing an exposure to industry challenges
- Past: develop workforce training programs for advanced manufacturing technologies and creating new job opportunities for current workforce
Visit the exhibits to meet suppliers, explore new technology, and ask questions of the experts.Halls A-C