Problem/Impact: The challenge during this Phase III project is to define and implement expeditious methods for the approval of new ADF-RP fabrication processes and engineered materials for use in replacement and repair of hard-to-replace legacy parts within the DoD maintenance and logistics organizations. ADF-RP processes include laser sintering (LS), electron beam melting (EBM), stereo-lithography (SLA), fused deposition modeling (FDM), direct metal deposition (DMD), ultrasonic consolidation, and production of rapid tooling and molds for traditional sand and investment castings.

Approach: Team pilots the building of net-shape and near-net-shape parts, directly or indirectly using ADF-RP, in parent alloys and engineered materials, evaluates materials and process performance parameters, addresses part qualification, and cooperatively (with OSD, DLA, Navy, Army, Marine and AF) define streamlined qualification and specification approval procedures for ADF-RP technologies. Install rapid tooling cell in at least one maintenance facility.

Benefit: Provide a solution to legacy part replacement, increased readiness, cost avoidance, production of CAD,
.stl or STEP files for future part production, and organic capability to implement ADF-RP through technology insertion and readiness to address repair or replacement of ADF parts in future advanced systems.

Implementation: Implementations currently in Navy and Army maintenance organizations.

Impact on Warfighter: Improved throughput cycle time and availability for field use.

DoD participation:

• U.S. Navy (TRF Kings Bay)
• U.S. Navy (NUWC Keyport)
• U.S. Navy (NFPC Philadelphia)
• U.S. Navy (NAVAIR China Lake)
• U.S. Navy (Portsmouth)
• U.S. Navy (Pearl Harbor)
• U.S. Navy (FRC East)
• U.S. Navy (FRC Southwest)
• U.S. Army (Anniston)
• U.S. Army (Tobyhanna)
• U.S. Army (Corpus Christi)
• U.S. Air Force (OC-ALC)
• U.S. DoE (Honeywell FM&T)
• NASA, Marshall Space Flight Center

NCMS Project Manager: Connie Phillips (386)445-2785