RARE Parts through RM&R – Phase IV

NCMS Project #: 140367

Problem: The challenge during this Phase IV project is to define and implement expeditious methods for the approval of new ADF-RP (Advanced Digital Fabrication through Rapid Prototyping technologies) fabrication processes and engineered materials for use in replacement and repair of hard-to-replace legacy parts within the DoD maintenance and logistics organizations.  See Figures for example parts.  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.

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.[1]

[1]  F-18 Fighter rocket launcher cooling ducts can only be produced by a laser sintering ADF-RP process.

Solution/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.

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

DOD Participation:

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

Industry Participation:

  • Pratt & Whitney
  • General Pattern
  • Lockheed Martin Missile & Fire Control
  • Baxter Healthcare
  • UTC Aerospace
  • Met-L-Flo
  • Applied Technology Integration
  • NCMS

Final Report Phase 1

Final Report Phase 2 – 4

Final Report Phase 2