Turning 10,000 AM components into full-scale manufacturing at GA-ASI

Common Atomics Aeronautical Methods, Inc. (GA-ASI) is a number one designer and producer of Remotely Piloted Plane (RPA) programs. In a chat on the AMUG 2023 Convention—one of the charming amongst a number of nice displays—GA-ASI’s Additive Manufacturing Division Supervisor Steve Fournier revealed precisely how deep GA-ASI’s dedication to AM goes, from polymer (FDM, SLS), to steel (L-PBF, DED-W), to composite tooling (LSAM, BJP). The following step is full workflow integration by way of a collaboration with the specialists and pioneers at Divergent, to implement their DAPS capabilities. “The way forward for AM,” Fournier stated, “is vivid”.

AM-centric

In 2021 Common Atomics Aeronautical Methods established a brand new Middle of Excellence for Additive Design and Manufacturing (AD&M). The Middle is targeted on rapid-reaction manufacturing of GA-ASI’s line of Unmanned Plane Methods (UAS) utilizing totally purposeful and flight-ready additive manufacturing functions, analysis and growth, large-scale tooling and next-generation flight {hardware}.

Over the previous decade, GA-ASI has invested within the onboarding of AM applied sciences, in addition to main the formation and speedy progress of a devoted division 5 years in the past. Fournier defined that the centralization of AM actions has confirmed to be a powerful catalyst for AM adoption, resulting in profitable initiatives in AM expertise insertion, software industrialization, flight {hardware} manufacturing, danger discount for R&D and data switch.

GA-ASI has certified over 350 flight parts throughout the totally different AM modalities used for manufacturing. To develop and qualify flight-capable AM functions, the corporate is increasing its AM ecosystem, which consists of the important thing components required for bringing an AM software from a prototype stage (print proper as soon as) to a production-level stage (print proper at all times).

Mr. Fournier revealed that GA-ASI is now additively manufacturing about 7,500 components per yr. Total, on their newest UAS platform, the MQ-9B SkyGuardian, the corporate has saved over $2 million in tooling prices and over $300,000 per plane in recurring price avoidance (with roughly 240 AM components on that plane platform). The variety of AM functions continues to develop quickly, fueled by the AM ecosystem, with greater than 10,000 additively manufactured parts on the plane it has produced. Particularly, the MQ-9B SkyGuardian and SeaGuardian fashions are main the business in the usage of AM components. In whole, AM parts already registered over 300,000 mixed flight hours.

“GA-ASI is frequently in search of methods to allow, speed up and combine Additive Manufacturing applied sciences into our designs, our operations and our merchandise,” defined GA-ASI President David R. Alexander. “By means of our AD&M Middle of Excellence, we’re utilizing a structured and stringent qualification course of for AM functions that ship a constructive enterprise case for us over typical manufacturing strategies. By means of a complete and holistic method, our staff of AM professionals are working to extend the adoption of AM components for the advantage of our plane and finally, our prospects.”

A basis for the long run

GA-ASI’s AM ecosystem has enabled the development of repeatable and dependable production-grade 3D printing throughout the firm, however this isn’t as simple as it might appear. The foundational ecosystem for AM at GA-ASI relies on a dozen totally different components, starting from materials allowables and equivalencies to R&D and CapEx funding.

This has been supplemented by ecosystem-controlled processes, the institution of an functions staff, and a well-defined enlargement roadmap. GA-ASI performs some recurring manufacturing actions at its AD&M Middle of Excellence, however the demand for rapid-reaction and low-rate manufacturing has required the event of a powerful AM manufacturing provide chain for the overflow manufacturing of advanced end-use thermoplastics and steel components.

As Fournier defined, “The depth of the AM ecosystem is restricted to every AM software and is pushed by [aspects such as] software mission criticality, qualification necessities from the airworthiness authority, QA/course of management availability and software monitor file.”

Extra particularly, the usage of AM in GA-ASI’s product lifecycle begins very early, even earlier than the product is even conceived. At a purely enterprise evaluation degree it helps to extend P-win. Within the idea section it helps to speed up time to market. Within the design section it additionally permits excessive integration. Coming to the precise prototype, it permits tool-less manufacturing. When it comes time to maneuver into manufacturing, AM performs a key position in decreasing prices for LRIP (low-rate preliminary manufacturing), additionally by way of tool-less manufacturing and excessive degree of integration. For a lot of of GA-ASI’s merchandise, these advantages proceed to be utilized at full manufacturing scale, leading to improved system availability, and particularly within the sustainment of current merchandise throughout their life cycle. The upper the mixing and half complexity, the clearer the AM’s worth proposition turns into. Right this moment AM represents about 1% of the invoice of supplies (BOM): the aim is to develop to five% BOM on bigger platforms and as a lot as 30% to 90% of BOM on small UAS.

Getting right down to the AM

What does all of it come right down to when it comes to the varieties of AM components produced? Taking a look at polymer AM applied sciences, completely thermoplastic-based, FDM is used primarily for half consolidation and substitution. This implies changing laminate components, creating massive conformal air administration programs, lamination tooling and tailored floor management gear. Future functions will embrace gasoline suitable (i.e. chemically resistant) supplies in addition to steady fiber-reinforced 3D printed components for steel substitute functions.

Polymer PBF functions (for now solely SLS) additionally embrace laminate half conversions whereas additionally leveraging the expertise’s better geometric freedom for advanced manifolds, conformal tooling and enormous ducting assemblies. Future growth will have a look at more and more massive assemblies. A very fascinating software is the collaboration with Hexcel to leverage HexAM expertise for the selective laser sintering of PEKK-based composites (initially developed by Oxford Efficiency Supplies) for the manufacturing of outer and internal mould strains (OML and IML). The advanced geometries enabled by AM offered design freedom and a neater manufacturing course of to enhance the efficiency and operation of UAV programs.

In metals, LPBF can also be primarily seen as an answer for components consolidation and substitution, with functions in laminate-to-AM conversions, built-in fluid manifolds, OML (outer mould line) fairings, in addition to engine and exhaust parts. One other very fascinating software is seen in built-in warmth exchangers (HX). GA-ASI partnered with Conflux Know-how on the design and manufacture of a brand new Gasoline Oil Warmth Exchanger (FOHE) for its MQ-9B SkyGuardian and SeaGuardian. Altogether the 2 firms have labored on 4 totally different AM tasks since 2018 and most not too long ago developed a chilly plate warmth exchanger that gives extra cooling capability for the high-dissipation Line-Replaceable Unit (LRU) utilized in numerous GA-ASI’s UAS platforms. The best way ahead for steel L-PBF functions consists of bigger consolidations, built-in gimbles and extra space functions.

Metallic DED expertise, which makes use of wire as feedstock, is seen as a possible key enabler for making massive components at considerably lowered prices. GA-ASI has been engaged on finishing the AM ecosystem qualification for titanium class A & B parts and on provider qualification in collaboration with Norsk Titanium. Different DED companions embrace Lincoln Electrical for functions centered on advanced INVAR and metal lamination tooling. Future progress is focusing on extra Inconel functions.

Many present AM functions at GA-ASI (primarily for tooling) additionally concentrate on large-format 3D printing applied sciences each in composites (LSAM) and sand (binder jetting). LSAM components, similar to these produced by Thermwood, are used for RT mill fixtures for composite laminate but additionally for some large-scale end-use assemblies, similar to floor functions measuring as much as 5 meters in size. Sooner or later, the scale of those components might develop to lengths of six to 13 meters. Sand binder jetting programs are used for as much as 2X-3X price financial savings on tooling and washout, with the long run aim of manufacturing masters and more and more personalized printers to satisfy particular necessities.

AM just isn’t the tip aim (digital design and manufacturing is)

As everybody concerned with AM is aware of very nicely, the implementation of a totally digital end-to-end manufacturing course of that features AM at its core is full of challenges that also should be overcome. The workflow should start with design for operate/AM/meeting, proceed via printing and ending, go on to speedy half inspection and high quality and at last implement course of integration to realize full automation.

To handle many of those challenges, GA-ASI formally partnered with Divergent Applied sciences, Inc. The corporate has developed a data-driven method to design, fabricate and assemble automobile buildings known as the Divergent Adaptive Manufacturing System (DAPS). GA-ASI is now seeking to qualify and implement this functionality to a few of its UAS platforms.

The joint growth program started in 2022 and led to a stronger strategic partnership on a number of platforms. The businesses have already accomplished two tasks resulting in a totally built-in small (<500 lbs.) UAS aerostructure, leveraging model-based, AI-driven and topology-optimized designs. The built-in steel construction was 3D printed (with printing instances under 13 hours per node), which led to the discount of the half depend integration by over 95% whereas assembly weight targets.

The DAPS course of inspected every printed element by making a full digital twin of the small UAS (SUAS) that was then utilized to a totally automated, tool-less robotic meeting course of that took lower than 20 minutes to finish. This course of enabled the staff to go from a print-ready SUAS design to a totally assembled deliverable airframe in lower than two days. GA-ASI anticipates this functionality will allow near-theater ramp capability sooner or later to help the warfighter.

This revolutionary method to design and manufacturing results in extremely built-in weight and performance-optimized designs which might be naturally, however not completely, leveraging AM applied sciences at a considerably decrease airframe recurring price, whereas offering a speedy tool-less iterative design method for a number of platform variants. “Industrial production-level AM is feasible for protection and civilian UAS, with a correct ecosystem utilized to AM use,” Fournier concluded, “nevertheless, AM shouldn’t be the tip aim however reasonably an enabling expertise suite supporting a totally digital manufacturing course of workflow.”