UNCLASSIFIED

UNCLASSIFIED

Distribution Statement A. Approved for Public Release. Distribution is unlimited.

FY17 Department of Navy Additive Manufacturing PrintFY17 Department of Navy Additive Manufacturing Print--aa--ThonThon

AM Mini SonobuoyAM Mini Sonobuoy

Project Description: Adapt emerging designs in transducer and

battery technologies into miniaturized sonobuoy components.

Using FDM and SLS technologies, these components will leverage

fabrication advantages of high-performance additive manufacturing

(AM) processes and materials.

Transition:

Proposed to PMA264 and PMA299

1 Year Development and Test Schedule

Design buoy internal componentsand modular container

Integrate into POD launcher

Perform testing on AM version ofcontainer

Incorporate into at-sea AMdemonstration

Business Case:

Alternative ASW platforms including UxVs need deployable andexpendable buoys small enough to meet platformsize/weight/power restrictions.

Existing fleet ASW air and undersea assets will be challenged tomeet a growing number of threats.

The ability to construct minibuoy containers aboard ships usingmature AM capabilities reduces logistics requirements wherestorage capacity is limited.

The Technology:

Industrial AM Systems: 3DSystems Vanguard si2 Selective LaserSintering (SLS) and Stratasys FORTUS 900mc AM platforms

AM Technology: Industrial-grade powder bed fusion and thermoplasticextrusion technologies.

Materials: Nylon 11, PC-ABS, ULTEM9085

Benefits:

AM provides the ability to design an expendable, part-countconsolidated, weight-optimized container

Functional AM container with integrated wiring, as-printed airchambers, and quick-assembly features allow for the small form-factor design.

Watertight construction to incorporate quick post-processing solutionsto seal/waterproof electronics.

Containers can be printed on-demand from at-sea platforms.

Challenges:

Container design to accommodate alldeployment scenarios (launch, waterimpact, etc.)

Flight certification for manned airplatforms

Maintaining backward compatibility withfielded ASW air systems that require RFcommunications

Everything you always wanted in a buoy...and less.

WILCOXON RESEARCHHIGH FREQUENCY VECTOR SENSORMODEL: VS-403WEIGHT (WITH CABLE & CONNECTOR):

24 GRAMS (0.85 OUNCES)

SSQ-53F DIFAR HYDROPHONEWEIGHT: 1,185 GRAMS (41.80 OUNCES)

SSQ-53F CO HYDROPHONEWEIGHT: 66 GRAMS (2.33 OUNCES)

WEIGHT (WITHOUT CABLE & CONNECTOR):12 GRAMS (0.42 OUNCES)

Enhanced Capability ConceptEnhanced Capability Concept