Large Format Manufacturing at the MDF · • Nearly 20% of the world’s manufactured value added....
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Large Format Additive Manufacturing at the MDF Alex Roschli Manufacturing Systems Research Group Oak Ridge National Laboratory July 2019 Oak Ridge, Tennessee
Transcript of Large Format Manufacturing at the MDF · • Nearly 20% of the world’s manufactured value added....
Large Format Additive Manufacturing at the MDF
Alex Roschli
Manufacturing Systems Research Group
Oak Ridge National Laboratory
July 2019
Oak Ridge, Tennessee
2 AM at MDF
Why is DOE so Interested in Manufacturing?
Manufacturing and materials R&D to:
• Reduce the energy intensity of U.S.
industry
• Support development of new
products
• Strengthen our nation’s
competitiveness and economic
vitality
Residential23%
Commercial18%
Transportation28%
Industrial31%
U.S. primary energy use by sectorSource: Annual Energy Review 2010, US EIA
Manufacturing Matters
• 12% of U.S. GDP
• 12 million U.S. jobs
• 60% of U.S. engineering and science jobs
• 57% of U.S. Exports
• Nearly 20% of the world’s manufactured value added
3 AM at MDF
Why should we go with additive?
4 AM at MDF
3D Printing Concrete
48-26-2009
5 AM at MDF
Big Area Additive Manufacturing (BAAM)
Large scale deposition system
• Unbounded build envelope
• High deposition rates (~100 lbs/h)
• Direct build components
• Tools, dies, molds
Carbon fiber material reduces warping out of oven
6 AM at MDF
Process Modifications
• Extrusion
– Single Screw Extruder instead of a Heated Nozzle
7 AM at MDF
Process Modifications
• Material Supply
– Pellets not Filament
– Low Cost Injection Molding Plastics
• $1 - $5 /lb
– Purchase by the Gaylord (1000lb)
8 AM at MDF
Low Hanging Fruit - Tooling
• NavAir Cherry Point
– Legacy aircraft tooling for sheet metal manufacturing
– Part model sent on Monday
– Parts printed on Tuesday
– Machined Wednesday and shipped
– First parts made on Friday
• Took Longer and Cost More to Ship than to Make
9 AM at MDF
Thermal Imaging of BAAM
10 AM at MDF
Partnership withCRADA
ORNL and Cincinnati Incorporated collaborate to create commercial large-scale system
Partnership to establish US-based large-scale AM equipment manufacturer
• Targets tooling lead time and cost reduction
• Cincinnati providing >$1M in cost share year one
– First large-scale polymer AM system delivered to MDF, April 2014
– Operational mid-May 2014
• Interest from multiple automotive, aerospace and tooling industries
• Stretch form and hydroform tools demonstrated
• Program started Jan 2013. Goal is commercial product Jan 2015 (24 months)
11 AM at MDF
CI BAAM Development Timeline
ORNL & Cincinnati Inc.Sign CRADA
Mar. Apr. Jun. Jul. Aug. Sept.Feb.
2014
Cincinnati Inc.Delivers Alpha I
to MDF
May.
ORNL Prints 1st Part on BAAM
Team Begins Software Dev.
Support GenerationSolved
Alpha II Build Started
Alpha II Sold and Delivered to
Chicago
From Signing to Technical Demonstration
In Front of 100000 People< 7 Months
12 AM at MDF
CI BAAM Development Timeline
13 AM at MDF
Mar. Apr. Jun. Jul. Aug.
2014
Cincinnati Inc.Delivers Laser Frame to
MDF
May.
Team Begins Software Dev.
Support
14 AM at MDF
Example for the need for modeling: Strati
• 7 Days and Nights of Printing • 1500+ lb of Plastic• Layer Times > 60 mins led to poor adhesion
and high residual stress• Over 26 miles of extruded material! • Toolpath and processing parameters impacts
internal stress
Need ability to model process, optimize toolpaths, reduce residual stress
16 AM at MDF
Slicing
17 AM at MDF
Preliminary 3D Finite Element ModelBig Area Additive Manufacturing
3D Model BAAM Print Parameters
Tool Path Generation
AutomatedFinite Element Mesh
Process & Damage Analysis
18 AM at MDF
Cobra
19 AM at MDF
BAAM Surface FinishTruDesign
20 AM at MDF
Additively Manufactured Integrated Energy
• Concept is to integrate energy of buildings and transportation using AM
– House has grid, solar and energy storage
– Car has natural gas hybrid electric
– Two way wireless power transfer between vehicle and building
• From concept to reality in 6 months
21 AM at MDF
Rapid ONR demonstration
• ONR wet sub 4 week demonstration project
– Rapid design and manufacture of submersible vessel for Navy
– Four week project
• Week 1 – 25 naval architects visit ORNL MDF for 5 days
– Learn design rules, design sub
• Week 2 – print sub (group of 7 stayed second week to help print)
• Week 3 to 4 – assemble and deliver sub
22 AM at MDF
Results
23 AM at MDF
Wind Turbine Molds
Traditional 50 m Mold 3D Printed 50 m Mold
Fabrication takes a total of 27 weeks
• 12 weeks: fabricate plug
• 3 weeks: setup and inspect to confirm shape
• 6 weeks: layup shell, attach frame, demold from plug
• 6 weeks: Electrical connections, cure, QA, shipping prep
Based on 13 m mold results, a 50 m mold can be
designed, printed and finished in only 20 weeks
• 12 weeks: print mold sections
• 4 weeks: glass and finish mold sections
• 4 weeks: attach frame, install heaters, QA,
shipping prep
1 pair of main plugs – reliable for 6 to 10 molds. On pair of
molds typically reliable for 1,000 blades
No plugs are needed. Direct CAD to mold
Wires are embedded into the fiberglass surface by hand
during mold fabrication to heat the surface
Air passages are incorporated into the design of the
mold to accommodate heated air which is cycled
throughout the mold
One section of the wind turbine blade mold
manufactured on the BAAM-CI from 20% CF-
ABS pellets
24 AM at MDF
Mold Fabrication: Heating (1)
Integral air heating
• Ducts designed into support structure for mold
form
• Eliminates embedded wiring and
electronics
• One printed piece has structure, ducting
and interfaces to truss structure
• Integral commercial inline blowers/heaters
complete the system
• Flexible, reusable - blowers and heaters
can be transferred from mold to mold as
opposed to embedded into each mold
permanently
• Confident strategy applicable for full mold.
25 AM at MDF
• Utilized 14 thermocouples (baseline measurements), thermal imaging and laser scanner to measure temperature and surface variations during heating
• Experimental validation
• Thermocouple data
• Laser profilometry data
• Thermal cycling trials
Experimental setup Laser tracker in foreground Thermal imaging on mold surface
Mold Fabrication: Heating tests (2) - GREEN
Surface temp Profile data
Results from all tests meet
design requirements
26 AM at MDF
Design Miami Pavilion
Was commissioned by Design Miami for it’s annual
meeting and was moved to the Miami Design District
to house and outdoor cultural program for the next
two years
27 AM at MDF
Gate Precast Concrete Mold Inserts
Domino Sugar Project
28 AM at MDF
Gate Precast Concrete Mold Inserts
Molds for precast concrete are typically manually assembled with sheets of plywood that are
surfaced with fiberglass-reinforced coatings (2-3 Weeks)
29 AM at MDF
Gate Precast Concrete Mold Inserts
< 24 Hours to Manufacture
30 AM at MDF
Man Machine Interface (MMI)
Shown Extended
Modular, Removable
OCILOW Pod (4 each)
Motor Drive
Electronics
Batteries
MMI stowed
Force sensors at
each pod
• Demonstrated on all-electric vehicle with 10,000 lb payload capacity. Demonstrated at sea on the U.S.S. Red Cloud
Holonomic Omnidirectionality Using Conventional Tires (ONR)
31 AM at MDF
ORNL People Mover
32 AM at MDF
Rapid Progress in BAAM
• January 2013: Prototype system at ORNL
– 7’ x 7’ x 5’ build volume
– 10 lb/hr deposition rate
• September 2014: Alpha CI-BAAM
– 7’ x 13’ x 3’ build volume
– 40 lb/hr deposition rate
• July 2015: Beta CI-BAAM
– 8’ x 20’ x 6’ build volume
– 100 lb/hr deposition rate
• March 2017 BAAM-B
– 7’ x 13’ x 8’ build volume
33 AM at MDF
BAAM is an Industry
Research Institute
Production Facility
Service Bureau
Large Scale AM Distribution Map
Material Provider
Equipment Man.
34 AM at MDF
Inspiration for Large Scale Fieldable Printing
Torbjörn Ludvigsen’s Hang Printer
35 AM at MDF
Cable Driven BAAM (CDBAAM)
• Researchers at the MDF are currently working on creating a hanging large-scale, fieldable deposition system that will allow for full-scale automated construction of buildings.
– Implemented with conventional construction equipment
– Quick set up, minimal site preparation
36 AM at MDF
Cable Driven BAAM (CDBAAM)
37 AM at MDF
What’s next? Metal-BAAM!
• Large scale metal AM can enable complete disruption in numerous industries including construction
• Why? Part count consolidation.
– Each part number costs $25K/year to track inventory
– Every pound removed on the boom is a pound more of dirt that can be moved
– Reduction of parts and creation of digital inventory can revolutionize heavy industry
• Target was to print excavator at 2017 CONEXPO
38 AM at MDF
Metal BAAM Approach
• Hybrid technologies
– Exploring melt technologies (MIG, TIG, Laser hot wire), MIM materials, induction with aluminum serium
– Partners include GKN, Wolf Robotics, Caterpillar, CCEPF, NFPA
– Target is 100 lb/hr at under $10/lb with 1000 cubic foot build volume
– Defining new toolpath generation strategy based upon low order thermal modeling to reduce residual stress
– Initial DOE investment ~$2M/year. Will grow significantly. Leveraging HPC for modeling, SNS and HFIR for residual stress measurements
39 AM at MDF
Metal BAAM business case• AM is great for low volume, complex parts
– Tooling and end use parts
• Tooling: All automotive OEM’s spend ~$200M/yr on tooling for each model (steel). Lead time is 2 years. Low volume tooling is closer to $20M (aluminum)
– Stamping is long term goal but compression forming, hydroforming, casting…
– Anticipating an automotive tooling gap (demand exceeding capacity)
– Construction: Each OEM (CAT, Deere, CNH…) spend ~$25K/year on each inventory number
– Aerospace: Titanium at GKN St. Louis
– Produce 1 million tons of chips per year
» Virgin material is $25/lb, sell chips at $1/lb
» High buy to fly (10:1 average, high end parts exceed 300:1)
– Machine at approximately 3 lb/hr
– Replace tools every 20 minutes
40 AM at MDF
Wolf Robotics CRADA• Robotic MIG arc welding
• Named Best New Technology at 2016 FABTECH
• Using process modeling and simulation for
– System design
– Development of design rules
– Toolpath generation (thermal based CAD to part)
– Have manufactured a 400 lb, 7 ft tall steel part
• Working with Dassault on modeling
– Using HPC for models
– Using thermal imaging to validate thermal predictions and neutron imaging to validate predicted residual stress
41 AM at MDF
Stick Print
42 AM at MDF
CONEXPO• Largest construction exhibition in Las Vegas
• Demonstrating multiple technologies
– Polymer BAAM for CAB
– Concept Laser for heat exchanger
– Wolf metal BAAM for stick
43 AM at MDF
Rapid Progress in Technology
44 AM at MDF
AME – 3D printed excavator
