Wednesday, December 6 | 2:00 PM Advanced Manufacturing Workshop
• Tim Shinbara, Vice President ‐ Manufacturing Technology, AMT • Majid Babai, Advanced Manufacturing Chief, NASA Marshall Space Flight Center • Ross Dickson, Product Line Manager, Wind River • Robert Taylor Ph.D., Adjacent Technology Lead, Space Antennas, Harris Corporation National Aeronautics and Space Administration Marshall Space Flight Center Additive Manufacturing at NASA/MSFC Transforming Design & Manufacturing
Majid Babai Advanced Manufacturing Chief NASA / MSFC Agenda
• Our History in AM • Our AM Efforts • Manufacturing “In Space” • Manufacturing “For Space” • AM Developments and Goals • Hybrid AM Developmental Efforts (Collaboration with DMG MORI) Additive Manufacturing History at MSFC
• Extensive experience in Additive Mfg. (AM) design & process development
• Experimented with over 30 AM technologies/systems in the past 26 years
• Capital investments in Powder Bed Fusion hardware, engineering, facilities and testing ($56M in the past 4 years).
• Have the largest commercially available PBF system in Metallic and the largest commercially available polymer AM system
2000 2010 Additive Manufacturing at MSFC Objectives: To develop, demonstrate and evolve Additive Manufacturing as a key component of an integrated engineering solution and risk reduction for affordable manufacturing for space transportation systems, and manufacturing in reduced-gravity environments.
For-Space
In-Space
National Aeronautics and Space Administration AM Manufacturing “IN-Space”
Why is it important? AM is a critical technology for deep space explorations, part replacements, tools and habitats. 3D Print Technology Demonstration • First manufacturing capability in Space (International Space Station) • Presently have two 3D printers on Space Station and two more are in works. One of which is a 3D printer and recycler (all in one).
3D Print Flight Unit with the MSG Engineering Unit in the background AM Manufacturing “For Space”
NASA MSFC is looking to Additive Mfg. and innovative designs to reduce manufacturing cost and schedule and help affordability of access to Space.
Major Efforts Include:
• Implementation of AM components for next generation of rocket engines
• Characterization of applicable alloys in AM
• Rationales for flight certification for NASA and our vendors
• Risk reduction and data share in pursue of smart vendor base
• Development of new alloys for AM processes (i.e. copper)
• Next generation AM technologies (Additive/Subtractive System)
Embedded Video MSFC AM Machines: Polymer
3D Systems Viper Stratasys Fortus 900mc
3D Systems SLA 5000 Video MSFC AM Machines: Metals
Concept Laser X‐Line 1000R
Concept Laser M2
ARCAM S400 Video Concept Laser M1 EOS M290 Significant Effort in AM Characterization
Performance
Powder
MAPTIS
Characterization Process Parameters
Dimensional & Digital Thread NDE Inspections
Heat Treatment
Test & Properties Surface Finish Microstructure What is MSFC’s Role in AM ?
• Risk Reduction & Technology Transfer • Vendor Development & Smart Buyer • Certification Rationale & Guidance • Anomaly Resolution
Image Credit: Aerojet Rocketdyne Bi-metallic AM Development • Although SLM/Powder Bed Fusion satisfies a lot of AM manufacturing needs, it has limitations. • Some limitations are; build envelope size, surface finish requirements, speed, component design or multi-material nature of application. • Some of these issues have been solved and demonstrated by the following collaboration between NASA and DMG MORI Utilizing DMG MORI LT4300 system DMG MORI Hybrid System (LT4300)
E
Embedded Video
• Integrated machining/grinding during build • Single build from multiple alloys • Graded alloys • Build on existing substrates/repair • High deposition rates • Lower cost metal powder • Large build volume and scalability Bi-metallic AM Development
DMG MORI LT4300 Bi-metallic AM Development Fabricated Two ASI Bi-metallic AM Development
Optical microscopy images of bond area Bi-metallic AM Development
LOX feedline Igniter test fixture for hot fire testing LH2 feedline
Igniter Spark Plug
Figure 1. -fire testing. Bi-metallic AM Development
33 Hot-fire Test (July12, 2017) Infrared image of igniter exhaust flame
Videos Large Scale Composites Mfg. Large Scale Composites Mfg. Manufacturing Mfg Planning and Structured Light Scanning Additive Manufacturing Simulations Execution •Drive Mfg Processes •Technologies •SLM •Facility Verification •Paperless delivery of work •As‐Built CAD Parts •EBM instructions •FDM •Kinematic Analysis •As‐Built CAD Assemblies •Controls Build of Engineering •Materials •Interference Analysis Released Data •Virtual Fit Checks •Titanium •Aluminum •Off‐line Programming •Process Planning, Execution, and •Mfg Tooling Setup/Verification •Inconel Quality •Plastic •Assembly/Disassembly Verification •Reverse Engineering •As‐Built BOM and Data Package •Uses •Model‐based Instructions •Quality Inspection and Acceptance •Rapid Prototypes •Complex Part Mfg •Facility/Equip Modeling (MAF) •In‐space Manufacturing
12/21/2017 Four Technology Areas –One Solution 22 Bi-metallic AM Development
Successful Test Results
The second additively built bi-metallic igniter, first of its kind was installed and test fired successfully 33 times at NASA MSFC propulsion test facility in July 2017. These were low-pressure, hot-fire component testing to simulate the cryogenic tank-head operation of the igniter during engine start-up. Place image here (13.33” x 3.5”)
ADVANCED MANUFACTURING FOR SPACE ANTENNAS
DECEMBER 6, 2016 Building Space Structures with the Latest Tools
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Each day, more than 87,000 The safety of over a billion people in the flights arrive safely, using Harris Eastern hemisphere draws on weather networks forecasts from the Himawari-8 satellite, featuring the Harris-built Advanced Himawari Imaging instrument
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Large Gossamer Antenna Reflectors • Focus microwave energy from feed horn into beam 22m MSV Unfurlable Refle • Graphite tube structure supporting fine wire mesh • Mesh stabilized and supported by tensile cord network Manufacturing • Large areas of seaming done by hand • Integration is 300 lb of materials over 100,000 ft3 • Metrology is critical (laser trackers and photogrammetry) Components • Metal fittings, motors, gears, tubes, mesh, and cords • Multiple technologies and projects
Difficult to apply mass production and automation techniques to highly specialized work
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Large electronics box with external phased array elements • Supports multiple missions using reconfigurable cards • Carried on all 72 Iridium Next satellites Manufacturing • Constellation size enables economies of scale • Production electronics built on automated lines • Primary housing machined from monolithic aluminum block • Engineering support maintained through production • Production floor staged in separate rooms • Integrated rolling cart has rollover capability Lessons learned • Completion of all units on time • Ability to implement additional payloads during run
Manufacturing constellations still has more in common with one-off manufacturing than true mass production. Technology to Connect, Inform Non-Export Controlled SpaceCom 2017 | 30 and Protect Information Additive Manufacturing (AM) Simplifying Complex Parts Appropriate for parts with small, complex features • Small moving assemblies • Cord networks • RF feed components Titanium direct metal laser sintering (DMLS) • Excellent material properties • Fast fabrication Stereolithography • High precision, complex parts Many-part fitting redesigned to single D • Used primary in microwave applications • Metal coated for elements or bare for supports Qualification and testing critical – three spaceflight markets • Exquisite space, NASA and other government agencies • Commercial space, for-profit companies • NewSpace, small satellites and risk-taking companies
Metal AM blends well with space manufacturing – except for qualification Print of DMLS test rods for qua . . . Technology to Connect, Inform Non-Export Controlled SpaceCom 2017 | 31 and Protect Information Advanced Manufacturing of Microwave Components
Very small feature size for Ka-band to W-band • 1 cm to 0.3 cm wavelength • Phased arrays with many patch or dipole elements • Waveguide and waveguide components Unusual processing and fabrication steps • Metal coating • Micron scale lithography • Integral fabrication of multiple materials Feed Array Built with SLA Enabling for many microwave components
Wideband FeedWideband Feed Array for NASA program Phased array unit cell shown with permission from TechnologySciperio to Inc. Connect, Inform ArrayNon-Export Controlled SpaceCom 2017 | 32 and Protect Information AM Parts for Commercial Space
Qualification is not as rigorous • Part qualification is typical • DMLS settings and orientation are important ‒ Same part, same machine at different vendors yield different results Common parts are considered non-structural • Require fine detail or structures that cannot be machined • Often reduces costs significantly Harris has invested significant resources to be successful • Powder analysis to determine compliance to specification • Electron microscopy to reveal inner structure and crystallography • Testing to determine mechanical performance Results: numerous parts have significantly reduced cost • Fixed Mesh Reflector (FMR) cord supports • Small reflector hinges and fittings • Feed and waveguide components
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Space compatibility is still required • Low-volatility thermoplastics represent outgassing threat to other systems • Structural properties must be sufficient to survive launch • Materials must survive high temperatures on orbit • Windform XT material for SLS meets NASA environmental requirements ‒ Allows use on cubesats launched by NASA, not certified for critical NASA structures Material qualification and processes are defined by program • Different metrics become important ‒ Cost is more critical than reliability ‒ Simplicity is more important than performance • Certificates of compliance that cost more than the part are eliminated NewSpace is driving innovation and cost for other sectors • What risk is acceptable? • Few Harris examples Technology to Connect, Inform Non-Export Controlled SpaceCom 2017 | 34 and Protect Information AM Parts for Exquisite Space - Structural
High reliability and consistency are essential • Aerospace industry was built on ability to produce high-performance, dependable materials • Methods for qualification not developed with AM in mind ‒ Adaptation has been achieved for high-value applications ‒ Materials are titanium and steel using electron beam and laser sintering • Issues have been experienced ‒ Powder quality and consistency ‒ Virgin vs. recycled material ‒ Mixing and contamination of powder ‒ Settings, orientation and calibration of machines Specifications and process controls are not standardized • Different proprietary technologies for suppliers • Very different than testing and qualification standards in the past Penetration of AM for NASA and government customers limited • Will only occur where value added is high • Involves individual part testing and qualification Technology to Connect, Inform Non-Export Controlled SpaceCom 2017 | 35 and Protect Information