IMTS 2022 Conference: DED Manufacturing of Large Critical Components – Pushing Boundaries of Metal Additive Manufacturing (AM) - Aerospace Manufacturing and Design

2022-07-22 21:59:24 By : Mr. Jeff Meng

Learn how metal additive manufacturing can create large, critical components.

This presentation focuses on large metal part additive manufacturing with newly developed multi-nozzle directed energy deposition (DED) manufacturing technology. Recent advances in technology now make large part printing economically feasible and technically superior. The presentation showcases the additive manufacturing of NASA’s RS-25 engine nozzle liner. This part is 111″ tall, has a 96″ base diameter, and weighs about 4,100 lbs. The build approach of this liner is discussed to highlight various challenges to large part printing and strategies adopted to mitigate these challenges. The goal of the presentation is to bring awareness to capability advancement of metal additive manufacturing (AM). This is achieved by demonstrating the ability to print large complex parts with difficult materials while targeting critical industry applications. At the same time, the presentation aims to educate attendees of the various challenges presented by large-scale printing, and how industry partners are working together to solve these problems. Last but not the least, the presentation shows how various industry teams came together with government agencies to advance existing technologies and develop new ones to solve difficult manufacturing challenges and advance metal AM to a new level of manufacturing.

Meet your presenter Bhaskar Dutta is the president and COO of DM3D Technology. Dutta has more than 30 years of experience in the field of metallurgy and metal processing, including 17 years in the AM industry. He has multiple technical publications and presentations in the field of AM, as well as two co-authored books and several book chapters. He also has five patents and five pending patents on metal AM. He is a member of ASM International and AMPM Program Committee. Bhaskar was on the winning team for SME’s Aubin AM Case Study Award in 2021.

Farhad Ghadamli is the lead AM engineer at DM3D Technology. During his professional career, he worked with different 3D printing equipment manufacturers as well as Eaton Polymer and Nanocomposite group and Eaton Additive Manufacturing Center of Excellence in Southfield, Michigan. He has experience with various technologies, such as FDM, DLS, DMLS, SLS, SLA, Bound Metal Deposition, Binder Jetting, and Direct Metal Deposition (DMD). Ghadamli has a Master and Bachelor of science in mechanical engineering from the University of California, Davis. In 2021, he was one of the recipients of the SME's Aubin AM Case Study Award as well as SME President's award for his work as the chair of Metro Detroit SME. He was recognized as one of 2015 SME 30 under 30 Future Manufacturing Leaders.

Mark Lewan is a senior engineer at DM3D. He is responsible for design engineering, CAD/CAM software, and the machining department at DM3D. Lewan has 31 years of industry experience, including 20 years in AM. Mark co-authored multiple publications and has three patents and two pending patents on AM technology. Mark was part of the winning team for SME’s Aubin AM Case Study Award in 2021.

Robert Fortuna is the production supervisor at DM3D. He is in charge of all production AM work. He has 41 years of industry experience including 15 years in AM. Prior to DM3D, Fortuna worked in various industries including laser welding machine building and laser welded filter assembly. Fortuna was on the winning team for SME’s Aubin AM Case Study Award in 2021.

Vijayavel Bagavath Singh is senior manager – DMD Systems in DM3D Technology. He is responsible for design and building of DMD Systems. Singh has a Master of Electrical Engineering with 26 years of controls engineering experience. His fields of expertise include Metal 3D Printing, Laser, CNC & Robotic processes. He co-authored multiple publications and has two patents and four pending patents on AM technology. Singh was on the winning team for SME’s Aubin AM Case Study Award in 2021.

About the company DM3D Technology LLC is an additive metal 3D company that uses laser based direct metal deposition technology (DMD) to form functional metal parts directly from 3D CAD data. Unlike other technologies such as laser sintering or binder jetting, DMD technology produces fully dense metal parts with a strong metallurgical bond to the base material resulting in production parts. DM3D’s expertise and innovation, which is protected by its patents and highly proprietary trade secrets, give the company its competitive edge in the marketplace.

Companies also to collaborate on propulsion technologies for next-gen, climate friendly regional aircraft.

Deutsche Aircraft has selected the PW127XT-S engine from Pratt & Whitney Canada, a business unit of Pratt & Whitney, to power the D328eco regional turboprop. The engine will be another model in the XT series which delivers a significant improvement in operating costs and sustainability. The PW127XT-S will be developed according to the D328eco timeline.

“We have worked closely with the D328eco team over a number of years to develop the best engine option for the aircraft,” says Maria Della Posta, president of Pratt & Whitney Canada. “The PW127XT-S provides airlines 40% more time on wing, a 20% reduction in maintenance costs with only two scheduled events over 10 years, and a 3% improvement in specific fuel consumption. We support Deutsche Aircraft’s vision of building a green aviation company and we’re confident that the PW127XT-S is the ideal match for the D328eco.”

“In addition to the engine selection, Deutsche Aircraft and Pratt & Whitney Canada will collaborate on novel propulsion technologies for next generation, climate friendly, highly efficient regional aircraft,” says Dave Jackson, managing director, Deutsche Aircraft. “Turboprop technology remains the most efficient and eco-friendly form of regional air transport available in the world. Our two companies recently agreed to cooperate on enabling the PW127XT-S engine powering the D328eco to run on a 100% sustainable aviation fuel (SAF) including hydrogen-based Power-to-Liquid (PtL) fuel.”

Modern regional turboprops consume 40% less fuel and emit 40% less CO2 emissions than most in-service regional jets on flights up to 400nm. Both companies are convinced of the need to further invest in this segment to continue to improve efficiency and reduce the impact on the environment. Pratt & Whitney Canada and Deutsche Aircraft agreed to continue working together to jointly develop a technology roadmap for implementation, test, and verification of Pratt & Whitney Canada’s innovative propulsion technology, within the D328eco program.

Specifically, the roadmap will focus on the capability to operate the two most promising net zero/zero CO2 fuels: PtL and hydrogen, respectively. The parties will assess the impact of these fuels and related technologies and operations to derive the requirements and solutions for the application.

“We seek not only to achieve the maximum CO2 emissions reduction possible, but also look for real operative propulsion efficiency improvements compared to today’s technology. This would mean a reduction in the order of 15% to 25% block energy on a typical regional mission,” Jackson added.

Della Posta said, “It is key that the major airframe and engine OEMs set out ambitious yet realistic timelines and capabilities to use novel propulsion technologies in combination with de-carbonized fuel capabilities. Pratt & Whitney Canada is committed to continuous improvements in the efficiency and sustainability of its products and services, for customers in all market segments.”

Learn about how next-generation production monitoring delivers insight into unattended operations.

About the presentation Unattended operations are the holy grail for today’s precision manufacturers. Running computer numerical control (CNC) machines without needing additional workers means more output for the factory. The downside is events can happen when no one’s around, and without an observer, it becomes an exercise in sleuthing to determine the cause for issues and stoppages. Unfortunately, first-generation production monitoring requires operator input to provide context around machine downtime and interruptions in production. When operators are required to enter reason codes to deliver understanding about machine states, manufacturers implementing unattended shifts are blind to a lot of issues that happen when nobody’s watching the machines. Next-generation production monitoring systems offer the perfect solution. By connecting to CNC machines and using the data directly from machine controllers, next-gen production monitoring solutions use machine learning to make sense of data in real time. Now, manufacturers can see what happened in an unattended shift for every part produced and downtime or stoppage that occurred. In this session, attendees will learn how next-gen production monitoring delivers insight into unattended operations, including the ability to monitor production in real time.

Meet your presenter Greg McHale founded Datanomix on the premise that the 4th industrial revolution would require turnkey products that integrate seamlessly with how manufacturers work today. He brings enterprise data skills to a market ripe for innovation. McHale held engineering leadership positions at several venture-backed companies and is a graduate of Worcester Polytechnic Institute.

About the company Founded in 2016 in New Hampshire, Datanomix offers automated production intelligence for precision manufacturers. When we started Datanomix, we met with dozens of manufacturers who were trying to use data from their equipment to optimize operations. Not one company was getting what they wanted out of their existing monitoring systems ? information was either too complicated and cumbersome, or too simple and not insightful. To add insult to injury, the user interfaces on those systems made it look like those companies just didn’t understand manufacturers. Based on their input, we built a system that was designed with a few key principles:

?       The system would require no human input for the data to be useful

?       The information provided by the system would be actionable right now

?       The system should be a “member” of your team, capable of providing answers and insights in the way you think about your business

777-200ER marks 10-year anniversary of ecoDemonstrator program.

Boeing unveiled its 2022 ecoDemonstrator with a livery that honors a decade of testing to reduce fuel use, emissions, and noise. The latest ecoDemonstrator, a Boeing-owned 777-200ER (Extended Range), will test about 30 new technologies aimed at improving sustainability and safety for the aerospace industry, including a water conservation system and technologies to improve operational efficiency.

"Boeing is committed to support our customers and enable the commercial aviation industry to meet our shared commitment to net zero carbon emissions by 2050," said Stan Deal, Boeing Commercial Airplanes president and CEO. "The ecoDemonstrator program's rigorous testing of new technologies further enhances the environmental performance of our products and services and is invaluable to continuously improving safety."

During six months of flight and ground tests starting this summer, the 2022 ecoDemonstrator will evaluate: 

• In collaboration with NASA, SMART vortex generators – small vertical vanes on the wing – that improve aerodynamic efficiency during takeoff and landing

• A system to conserve onboard water and reduce weight as well as fuel use

• Additively manufactured airplane and engine parts to help reduce fuel use and manufacturing waste

• An environmentally preferred refrigerant and a new fire suppression agent to reduce greenhouse gas emissions

• A head-up, enhanced vision system for pilots to improve operational efficiency

• Continued comprehensive study of the impact of sustainable aviation fuel toward the reduction of emissions

• For all flight tests, the 777-200ER will fly on a highest approved blend of sustainable aviation fuel (SAF) available

"The Boeing ecoDemonstrator program brings together the two most important ingredients to a more sustainable future – innovative technologies and partnerships with customers, suppliers, government agencies and academia," said Chris Raymond, Boeing chief sustainability officer. "We celebrate the past successes and look forward to continuing this iconic program to help decarbonize aviation, together."

Since its initial flights in 2012, the Boeing ecoDemonstrator program has accelerated innovation by taking new technologies out of the lab and testing them in an operational environment. Including this year's platform, the program has tested about 230 technologies to help decarbonize aviation, improve operational efficiency and enhance safety and the passenger experience. Approximately a third of tested technologies have progressed onto Boeing's products and services.

Learn how to use technology to fill the experience gap created by the machinist shortage.

About the presentation The shortage of experienced manufacturing professionals is an issue manufacturing shops have been facing for years. As the current workforce of NC programmers and machinists gets ready for retirement, there’s less and less talent coming in to take their place. While the push to develop additional paths through education and training is underway, what can shops do in the meantime to collect and protect their current machining expertise while meeting increasing demands for speed, quality, and innovation? One solution is adopting advances in technology to develop smarter machining processes. Huge advancements in manufacturing software have made it easier for shops to verify toolpaths, simulate machine movement to avoid crashes and unexpected behavior, and optimize NC programs and feed rates to ensure cuts are performed without breaking the cutter or causing undue wear – all without requiring NC programmers and machinists to have expert machining experience. The presentation will explore the benefits of using software to establish "smarter" manufacturing processes to enable more quality production with fewer resources.

Powered by AMT and managed by GIE Media, The IMTS 2022 Conference features 69 different sessions you won’t want to miss so register today. Focused on a range of topics that include process innovation, plant operations, quality/inspection, and automation, The IMTS 2022 Conference addresses improving productivity; improving part quality; and developing a stable, competent workforce to lower the cost of manufacturing in the United States and create new levels of market demand.

Meet your presenter Gene Granata, director of product management, has been with CGTech since 1992. With more than 30 years of CNC manufacturing experience, Granata is responsible for planning development of CGTech’s flagship software product VERICUT, and associated CAD/CAM and Tooling interfaces. After receiving his Bachelor of Science degree with an emphasis in NC Manufacturing Technology from Northern Illinois University in 1983, his professional career began at Bendix Aerospace (now known as Honeywell Federal Manufacturing & Technologies) as an NC programmer for a variety of CNC lathes, mills, and multi-tasking machines. He then went to work for aerospace companies such as Northrop Aircraft and McDonnell Douglas, working on T-45, F-20, and F-18 fighter projects, as well as B-2 Stealth Bomber and C-17 military transport aircraft. Prior to his role as director of product management, he was VERICUT Project Manager and wrote technical documentation, designed many general-purpose and customized training courses, and provided manufacturing consulting services to hundreds of companies in virtually every industry.

About the company Headquartered in Irvine, California, CGTech specializes in numerical control (NC/CNC) simulation, verification, optimization, and analysis software technology for manufacturing. CGTech was founded in 1988. Since then, our main software product, VERICUT®, has become the industry standard. With offices worldwide, VERICUT software is used by companies of all sizes, universities/trade schools, and government agencies.