Brian A. Czapor 300 College Park Dayton, OH 45469-000 brian.czapor@udri.udayton.edu

1. Additive Manufacturing of Multi-Scale Composites Brian A. Czapor 300 College Park Dayton, OH 45469-000 brian.czapor@udri.udayton.edu

2. Agenda • Introduction to Fused Deposition Manufacturing • Ohio Third Frontier (OTF) – Advanced Materials for Additive Manufacturing Maturation • National Additive Manufacturing Innovation Institute (NAMII) – Maturation of FDM Component Manufacturing

3. Built on FDM Technology Build Platform FUSED DEPOSITION MODELLING

4. Background – AM Technology

5. Fortus Thermoplastics Family ABS-M30 ABS-ESD7 ABS-M30i ABSi PC-ABS Polycarbonate PC-ISO ULTEM 9085 PPSF/PPU Soluble Supports* Fortus Solutions

6. FDM Material Properties Strength vs Heat Deflection Flex Modulus vs Flex Strength 360 Flexible ULTEM 9085 350 400 PPSF 340 350 ABS ULTEM 9085 Flexural Modulus [KSI] 330 300 Heat Deflection [˚F] PC PC-ISO PC 320 250 PPSF 310 200 PC-ISO ABS Stiff 300 150 10 18 6 8 12 14 16 5 7 8 9 10 Flexural Strength [KSI] Tensile Strength [KSI] @ AMB

7. Modified Nylon FDM filament has 6.5X modulus increase and 2.5X strength increase

8. Ohio Third Frontier ProgramAdvanced Materials for Additive Manufacturing Maturation

9. Advanced Materials for Additive Manufacturing Polymer powder CNF/CNT Maturation Leading Ohio’s Innovation GE Aviation Engine Configurations Lockheed/Northrop F - 35 Honda Acura NSX OTF - ADDITIVE MANUFACTURING

10. Fused Deposition Modeling Stratasys, Inc. A KEY STRATEGIC ALLIANCE UDRI and Stratasys have formed a partnership designed to accelerate development and transition of new FDM materials for aerospace and automotive applications.

11. Supply Chain Developed for the OTF-IPP Nominal 500 pound lots

12. Program Status and Schedule Ultem 1000 selected for aerospace applications Commercial chopped carbon fiber and CNF/CNT’s used for reinforcements Property goals for first 500 pound scale-up batch: tensile test, 25 ksi strength, 2 msi modulus. FDM feedstock recently manufactured using ULTEM 1000 and CF that meets dimensional requirements. Feedstock development is ongoing.

13. National Additive Manufacturing Innovation Institute (NAMII)Maturation of FDM Component Manufacturing

14. Distribution A: Cleared for Public Release # 88ABW-2012-5792

15. NAMII Project Scope • Objectives • Enable OEMs to productionize FDM Hardware • Raise Manufacturing Readiness Level (MRL) of FDMTM technology for aerospace and defense applications from level 4 to level 7 • Build a platform for long-range technical and economic developments for Additive Manufacturing technology • Project Scope • Task 1: Design Allowables • Task 2: Certification Procedures • Task 3: Design Guide • Task 4: Validation • Task 5: Final Report Distribution A: Cleared for Public Release # 88ABW-2012-5792

16. Task 1 – Design Allowables

17. FDM Design Considerations

18. Sustainability Overview • DOE Sustainability Goals • Reduced lifecycle energy cost of the FDMTM process compared to parts manufactured using the alternate conventional manufacturing process • Energy efficiency of FDMTM manufacturing as compared to parts manufactured using the alternate conventional manufacturing process • Environmental sustainability impacts of FDMTM manufacturing • Industry Energy Savings • Reductions in material use compared to existing conventional manufacturing process. • Energy savings from material substitution, including reduction in fuel burn as a result of light-weighting structures. • Process energy of FDMTM manufacturing a part as compared to the conventional manufacturing process. • Reduction in water use as a result of using FDMTM manufacturing as compared to the conventional manufacturing process. • Plant energy savings due to process overhaul resulting from utilization of FDMTM manufacturing compared to the conventional manufacturing process. Distribution A: Cleared for Public Release # 88ABW-2012-5792

19. Workforce and Educational Outreach • Secondary Education • Module presented during summer camps held at the University of Dayton: focus on introducing high school students to careers in engineering. • Community College • Design Guide data & non-proprietary processes share with Sinclair Community College, Dayton, Ohio, which operates the National Center for Manufacturing Education (NCME) for workforce training in advanced manufacturing. • Undergraduate Education • University of Dayton undergraduate students will be employed to work on testing and design guide development phases; Inclusion of material in required seminar series for undergraduate mechanical and chemical engineering students. • Graduate Education • Design guidelines to be incorporated into new graduate course on AM at University of Dayton which will cover analysis, design, and processing of structures using Additive Manufacturing. • Workforce • Contribution to the creation of an engineering pipeline that is prepared to meet the demands of designing for Additive Manufacturing technologies. Distribution A: Cleared for Public Release # 88ABW-2012-5792

20. Outcome of NAMII Program Members of NAMII have the rights to use the IP to generate economic development UDRI can use the IP to help design components for industry clients RP+M can produce the components in Ohio

21. Future Development Opportunities Tooling for composites *(courtesy of Stratasys)

22. Sheet Metal ToolingDemonstrated Application Hydro Form Rubber Pad • Demonstrated Applications • Hydro Forming • Rubber Pad Forming • Demonstrated Tooling • Female, Blow Down Tools • Male Tools • Punch Tools • Pressure Intensifiers • Matched Male & Female Tools • Back Filled Tools • Demonstrated Conditions: • Range of alloys and thickness tested • Demonstrated forming pressures up to 10KSI • Variety of tools >100 cycles, some > 500 cycles • Large jointed tools have been tested Pressure Intensifiers Punch Blow Down Blow Down Male

23. Questions? Distribution A: Cleared for Public Release # 88ABW-2012-5792