Progressive Algorithms, a licensed Service Disabled Veteran Owned Small Enterprise that makes use of 3D printing for prototyping and design.
Meet Progressive Algorithms, a licensed Service Disabled Veteran Owned Small Enterprise that gives modern improvements for safety and protection. This firm has taken a low-cost desktop 3D printer and produced a secure finish product used as a element in a posh protection system. Be part of us to find how Progressive Algorithms graduated from experimental prototyping to completed product using 3D printing.
In trade, additive manufacturing and desktop 3D printing are used extensively within the design and prototyping section of a full product resolution. It’s a well-known that firms and/or organizations that don’t take part in these iterative prototyping processes are being left behind. Now, 3D printing has made inroads into the manufacturing course of, from the design and manufacture of jigs and fixtures to low price manufacturing of elements as a part of product assemblies. Progressive Algorithms, a modern supplier of improvements for safety and protection, has taken full benefit of 3D printing capabilities. With its Phalanx Protect™ resolution, desktop 3D printing has grow to be an integral instrument in offering superior capabilities and elements to the Division of Protection (DoD), Division of Homeland Safety (DHS) and different governmental companies and organizations.
The Phalanx Protect
Procurement of services and products within the DoD falls beneath the purview of the Protection Acquisition System. Acquisition of bodily merchandise on this area is analogous to the total product life cycle that’s widespread in most industries. The method begins the place wants and/or functionality gaps are analyzed and necessities are gathered to find out if present merchandise or options exist. If nothing exists to fulfill the acknowledged necessities, then the preliminary section of the product life cycle begins in earnest.
An instance of DoD’s product lifecycle in motion is of the Phalanx Protect™ resolution. The genesis of the Phalanx Protect™ may be traced to the previous expertise of Progressive Algorithms Founder/CEO, Jay Chesnut. Jay’s time as a Naval Aviator uncovered him to the necessity for improved, sustainable safety and surveillance programs that weren’t presently out there. On account of real-time occasions, Phalanx Protect™ was developed to enhance DoD’s and DHS’s present capabilities. Presently, Phalanx Protect™ has been examined and confirmed by two Expertise Readiness Assessments (TRAs) and is designated at Expertise Readiness Stage 8 (TRL 8), a stage the place options, interfaces, and supplies are confirmed and validated to help full manufacturing. What’s so outstanding in regards to the TRL 8 designation is that the present Phalanx Protect™ resolution has desktop 3D printed elements. At low manufacturing ranges, 3D printed elements will proceed to be a part of the top product. This leads to the financial savings realized by the avoidance of tooling and molds, and in addition in a value and time financial savings supplied by on-demand, Simply In Time (JIT) fabrication processes. The financial savings is a direct results of the introduction of 3D printing to the product lifecycle.
With the success of the Phalanx Protect™ resolution, Progressive Algorithms is exploring different areas during which 3D printing could also be utilized in different elements of the product lifecycle. Sustainability is one space that’s ripe for change the place product inventories are dictated and the restore and reconfiguration of present merchandise and options are facilitated by 3D printing. Regardless of the case, 3D printing is for certain to be an integral functionality as a part of the total product lifecycle.
Introduction
Procurement of services and products by the DoD is a bit more concerned than simply utilizing a bank card to buy on-line. Most of the merchandise which are wanted by the DoD, DHS and different governmental entities have specialised necessities that successfully exclude many off-the-shelf merchandise. Many instances this can be a results of the setting during which the product will likely be used. Usually when in harsh terrain or the place merchandise will likely be dealt with roughly, the answer will have to be “hardened” to resist shock, impression, temperature fluctuations and hostile environments. In consequence, new and/or present applied sciences have to be designed and fabricated not solely to function however to outlive in these adversarial circumstances. That is the rationale why many instruments and merchandise procured by DoD and different governmental companies have a better price than comparable options within the industrial sector.
With additive manufacturing and desktop 3D printing, the acquisition life cycle is poised to avoid wasting on the price of improvement, prototyping, fabrication, and sustainability of the product and product options compared to the normal life cycle. As well as, what is usually misplaced within the quantitative evaluation is the elevated productiveness, innovation, collaboration and improved high quality afforded by 3D printing. In response to Tasha Keeney, an ARK Funding Analyst, “3D printing will collapse the time between design and manufacturing. It’s going to shorten lead instances, cut back prototype prices, produce lighter merchandise and supply for better design complexity in manufacturing.” All of those parts are realized because of the capabilities that 3D brings to the procurement desk.
As within the industrial sector, governmental organizations are trying to know how 3D printing applied sciences will have an effect on the way in which they do enterprise and the way they’ll procure, deploy and maintain full product options over the life cycle of the product. Many envision a complete provide chain transformation of delivering fabrication capabilities nearer to the top consumer. Different areas of transformation embrace system upkeep, logistics and the power to provide hard-to-source elements. Even whereas DoD, DHS and different governmental entities are exploring how desktop 3D printing and additive manufacturing will have an effect on their acquisition mannequin, they are able to take some cues from their product suppliers within the industrial sector.
Downside Definition
The general acquisition problem is to find out how distributors, suppliers, and contractors will meet the wants of navy and governmental clients in delivering product options in a well timed method and at a diminished price.
Excessive-Stage Answer
Progressive Algorithms is a Service Disabled Veteran Owned Small Enterprise that gives modern improvements for safety and protection. The corporate realized that the one approach to ship merchandise and options on time and at diminished price was to make the most of the capabilities supplied by desktop 3D printing. In consequence, Progressive Algorithms has utilized a low-cost desktop 3D printer has taken an experimental prototype and delivered a completed product that’s getting used at present.
Through the improvement of the Phalanx Protect™ functionality, 3D printing was utilized from the beginning. In response to Progressive Algorithms Founder/CEO, Jay Chesnut, “3D printing gave us the liberty to innovate and take probabilities. Solely by 3D printing might we actively discover, progress and validate an entire resolution that exceeded the client’s wants and necessities.” Through the design and prototyping section (see Determine 2), 3D printing was pivotal within the iterative design course of. Iterative design will increase productiveness and innovation by permitting the designer to prototype and take a look at a number of choices earlier than narrowing in on a last design. It additionally improves the standard of the top product by ensuring that every one elements combine and function nicely earlier than spending assets on tooling and fabrication.
Preliminary Prototype
Through the previous 4 years, the number of supply supplies and filament for desktop 3D printers has elevated dramatically. The unique desktop filament picks of ABS and PLA have given approach to product prepared supplies equivalent to TPE, TPU, Nylon, PETG, and Polycarbonate. The product of alternative for the outside and inside casing of the Phalanx Protect™ sensor was PETG. “PETG has been an ideal materials to fulfill the necessities of sturdiness and skill to resist harsh circumstances required by our clients,” acknowledged Chesnut.
Outer Casing
PETG proved to be materials for prototyping in addition to a wonderful materials for the ultimate product. “We have now but to obtain an order massive sufficient to justify injection molding,” acknowledged Chesnut. “We have now already coordinated with a number of injection molders who will be capable of transition from 3D printing to full-scale manufacturing. In an effort to do this, we are going to want an order within the low tons of to justify utilizing injection molding. Since we take additional effort within the post-processing of the housing, most don’t even know they’re 3D printed. Those who don’t are shocked we have been capable of obtain such a excessive stage of high quality.” Progressive Algorithms realized that desktop 3D printing supplied a versatile finish resolution at an affordable price and with out having to allocate the time and assets essential for tooling, injection molding, and full manufacturing.
Accomplished Sensor Earlier than Exterior Ending
Answer Particulars
The Phalanx Protect™ unmanned floor sensor system was derived from a real-world want and developed and produced using superior applied sciences to incorporate desktop 3D printing. Earlier sensors lacked sturdiness and the aptitude to adapt to altering circumstances and community configurations. Options to this want have been then simply explored and developed using superior networking applied sciences, energy sources and 3D printing.
With 3D printing, speedy prototyping actually turned speedy. Designs have been configured, reconfigured and iterated every day. Useful prototypes using a spread of supplies and elements have been simply produced and variations have been positioned in a real-world A/B testing setting. The ultimate prototype and proposed resolution have been then prepared for Expertise Readiness Assessments (TRAs) on two totally different events whereas working by the DoD acquisition course of. Chesnut acknowledged that “3D printing supplied an infinite quantity of flexibility whereas going by the acquisition course of. We have been capable of higher outline the necessities and even adapt higher product kind and performance with out shedding any time through the course of.”
In response to Chesnut, “As we progressed from TRL 3 to TRL 5, we have been capable of iterate with totally different kind elements. Progressing from TRL 5 to TRL 8, we have been capable of fulfill ergonomic and tactile concerns to make a product clients wish to contact and really feel. Each firm desires a possible buyer to fall in love together with your product, or at the very least suppose it’s cool to the touch and maintain.”
The Phalanx Protect™ product resolution was capable of obtain a Expertise Readiness Stage 8 (TRL 8) with its present design using PETG as a 3D printed supply materials (see Determine 5). “PETG supplied the required tensile power and stability whereas leaving sufficient choices for buyer modifications earlier than we go to TRL 9,” acknowledged Chesnut. “That is the nice benefit of 3D printing earlier than transitioning to excessive price injection molding.”
Completed Product
Enterprise Advantages
The expertise of Progressive Algorithms with desktop 3D printing is just not distinctive. Many firms and organizations within the protection area are experiencing the identical outcomes. Organizations are recording price financial savings not solely on the design and improvement finish but additionally on downstream capabilities equivalent to manufacturing, fielding, and sustainment. Iterative, repeatable processes save time and speed up the velocity of innovation. Useful prototypes using a variety of supplies at the moment are the norm and product resolution firms may even discover the shape and performance of finish merchandise earlier than transitioning to full manufacturing. Mass customization and manufacturing on an as wanted, JIT foundation at the moment are doable. All of this has been realized on the preliminary insertion of desktop 3D printing capabilities.
Deliberate Subsequent Technology Design
Inside of Case for Deliberate Subsequent Technology Design
Abstract
The acquisition of services and products by the DoD, DHS and different governmental companies has simply skilled the primary wave of the results of additive manufacturing and 3D printing. Subsequent waves will embody, low quantity manufacturing, digital stock, product enhancement and obsolescence mitigation. From a listing perspective, the power to fabricate elements on-site might result in a big discount in extra stock. The Navy, for instance, discovered $7.5 billion price of extra stock in 2008.
This chance for price discount alongside all the product lifecycle is a large motivation for adoption of this expertise. In response to Lieutenant Commander Michael E. Kenney of the Naval Postgraduate College, use of additive manufacturing within the acquisition life cycle would produce a “…return on funding of 221.24%.” Commander Kenney additionally acknowledged that by additive manufacturing within the upkeep cycle“…the quantity of rework was diminished by 45%, affecting and thereby lowering the period of time to provide and restore elements from 39.5 man hours to 22.7 man hours, a discount of 57%.” These are highly effective arguments for the implementation and use of 3D printing applied sciences.
As additive manufacturing and desktop 3D printing capabilities have developed, so have the true world situations and finish use instances. Those who wait to trip the 3D printing expertise wave could be left behind. It’s crucial that every one product and repair producers discover the mixing of this expertise into their particular person enterprise processes to stay aggressive.
