Scalable Design for Manufacturing, Modeling Optimization for Additive Manufacturing
Navy SBIR 2018.1 - Topic N181-094
SSP - Mr. Mark Hrbacek - firstname.lastname@example.org
Opens: January 8, 2018 - Closes: February 7, 2018 (8:00 PM ET)
Information Systems, Materials/Processes
Strategic Systems Program (SSP) Trident D5 Missile
OBJECTIVE: Develop modeling
framework of design and analysis for the development of scalable lattice (or
cellular) architectures to optimize the weight, dynamic response and robustness
of structural components for missile applications. Deliver a tool that can
analyze the additive manufacturing process and verify within specific criteria.
Also, be able to compare products to existing designs and critically analyze
the components. Framework should be applicable for metals and composites.
DESCRIPTION: Advances in
Additive Manufacturing (AM), Topological Optimization (TO), and Digital Imaging
Correlation (DIC) technologies offer a unique opportunity to create a
synergistic impact in developing efficient structural designs that can adapt to
evolving technology elements and operational environments. For example, AM
facilitates rapid prototyping, and alleviates the design and logistics
constraints of the current manufacturing processes. Combination of AM and TO
using generative design allows for biologically-inspired designs such as
lattice (or cellular) that use highly ordered unit cells (trusses) to create
efficient structures oriented along the force field, rather than the properties
of the parent material. Furthermore, recent developments in measurement
technology such as DIC allow for better understanding of the structural
response of the complex topology of the lattice (unit cells) under static and
dynamic loading and provide for better model validation of such complex
structures. Overall, the coupling between these three technology areas may
potentially allow reduction in qualification time of these repeatable units.
PHASE I: Develop a proof of
concept modeling framework that can optimize missile structural component
design using various scales of lattice (or cellular) designs to minimize
weight; achieve a required stiffness, strength, and reliability; and meet
system structural and dynamic performance objectives with confidence levels.
Demonstrate the concept, for various scales, on a missile component object
provided by the Contracting Officer’s Representative (COR). Phase I will
include plans for a concept prototype to be developed during Phase II.
PHASE II: Mature concept
system architecture into a working design and analysis tool that will be used
to demonstrate optimized manufacturing concepts for missile structural
components. Focus initially on a single material for which AM processes are
mature, and expand the work to other materials as the offeror’s manufacturing
technology matures. Demonstrate the applicability of the Phase I-developed
framework/tool by designing, fabricating, and testing three different scales of
the missile component object. The Phase II effort will result in a final
PHASE III DUAL USE
APPLICATIONS: Manufacture full-scale structural missile component object using
this new lattice structure and AM modeling framework and subject them to flight
acceptance test program to develop a process for future use of this framework.
1. Suard, M.
"Characterization and Optimization of Lattice Structures made by Electron
Beam Melting." University of Grenoble Thesis. November 2015.
2. Nguyen, J., Park, S.,
Rosen, D., Folgar, L., and Williams, J. "Conformal Lattice Structure
Design and Fabrication." https://sffsymposium.engr.utexas.edu/Manuscripts/2012/2012-10-Nguyen.pdf.
3. Campbell, T., and Ivanova,
O. "Additive Manufacturing as a Disruptive Technology: Implications of
Three-Dimensional Printing.” Technology and Innovation, 2013, Vol. 15, pp.
4. Ford, Sharon L. N.
"Additive Manufacturing Technology: Potential Implications for U.S.
Manufacturing Competitiveness." United States Trade Commission, Journal of
International Commerce and Economics, Web version: September 2014. https://www.usitc.gov/journals/Vol_VI_Article4_Additive_Manufacturing_Technology.pdf
5. Sutton, M. Orteu, JJ and
Schreier, H. "Image-based Measurements in Solid Mechanics: A Brief
History, Static and Dynamic Application Examples and Recent Developments."
Published electronically at bssm.org. https://books.google.com/books?hl=en&lr=&id=AlkqMxpQMLsC&oi=fnd&pg=PA1&ots=5VdTgfvE_F&sig=gx4_kmU5t6zF5LzJ5DG0_sCdsV8#v=onepage&q&f=false
6. Reu, L., Sutton, M., Wang,
Y., and Miller, T. "Uncertainty quantification for digital image
correlation." Proceedings of the SEM Annual Conference, June 1-4 2009. https://sem.org/uncertainty-quantification-for-digital-image-correlation-7-pages/
7. Ghadbeigi, H., Goodall,
R., Khodadadi, M., and Jones, E. "Damage and deformation analysis of
Ti-6Al-4V Diamond lattice structures." http://www.bssm.org/uploadeddocuments/Conference%202015/2015papers/Damage_and_deformation_analysis_of_Ti-6Al-4V_Diamond_lattice_structures.pdf
Manufacturing; Topological Optimization; Digital Imaging Correlation (DIC)
Technologies; D5 Missile; Lattice Structures; Material Design; Model-based
Engineering; Material and Processes