The RAPID 2013 Conference & Exposition Directory - Society of ...

2:30–2:55 pm
Additive Manufactured Modular Telescoping
Wing Unmanned Aerial Vehicle
Michael Stern, Rapid Prototyping Engineer, MIT Lincoln Laboratory
Eli Cohen, UAV Test Engineer, MIT Lincoln Laboratory
We present a low-cost, highly flexible and modular Unmanned
Aerial Vehicle (UAV) for atmospheric sensing. A novel
aerodynamic design was realized with a lightweight, efficient
mechanical structure designed for and fabricated with additive
manufacturing (AM) to meet performance requirements. The
aerodynamic design features telescoping wings to permit both
dash and loiter flight depending on the exposed wing area
and airfoil. The aircraft structure is primarily Fused Deposition
Modeling (FDM) ABS-M30 with supplemental carbon fiber. The
total weight of the aircraft was seven pounds with a wing span
of 80". We designed the structure to be easily assembled using
only standard hand tools. The modular design permits rapid
reconfiguration of the aircraft and the ability to swap payloads
while simplifying replacement of damaged parts, even in the field.
Focus on frangible design prevents widespread damage and
minimizes rebuild in the case of failure. We completed several
test flights demonstrating the structural integrity of the AM parts
and the success of the overall design.
This work is sponsored by the Air Force under Air Force contract
number FA8721-05-C-0002. The opinions, interpretations,
recommendations, and conclusions are those of the authors and
are not necessarily endorsed by the United States Government.
3–3:25 pm
Global Advances in Metal Additive Manufacturing
for Final Part Production
Tim Caffrey, BS, Associate Consultant, Wohlers Associates
Applications for metal parts built by additive manufacturing
have developed quickly in the decade or so since metal AM was
introduced. The technology for the production of parts that go
into final products is also growing at a fast pace. Caffrey will
discuss materials, processes, systems, and current applications
for final part production in the aerospace, medical, dental, and
jewelry industries around the world. The presentation will also
cover the current and future challenges of manufacturing with
metal AM processes.
3:30–3:55 pm
Additive Manufacturing—A Critical Review
Walter J. McGee, FIAE, Sr. Design Check Engineer II,
Raytheon Space & Airborne Systems
In evaluating the potential of AM and MBD as the wave of the
future, it is vital that adequate attention be given to both the
benefits and challenges these technologies present. These
technologies offer the possibility of paperless engineering and
more cost effective manufacturing of complex or small quantity
parts. However, along with the significant savings potential,
these technologies raise some important questions. For example,
are new methods/equipment needed to accurately measure the
size and shape of more complex geometries? What changes are
needed to qualify AM materials and processes to allow broader
use in prime hardware? How should paperless companies
prepare for a natural or terrorist event that could destroy
electronic technical data?
This report will consider a few of the questions that should
be asked when weighing the costs/benefits of adopting these
new technologies.
4–4:25 pm
Sustainable Cars and the Future of Manufacturing
Jim Kor, P.Eng., President, KOR EcoLogic
For URBEE 2, KOR EcoLogic has made a mental leap. They are now
designing the car so that the major body and interior parts (about
40 to 50 parts in total) MUST be made by the 3D printing process.
No other process will be able to make parts as complicated as
they plan to design. This is quite different than rapid prototyping
a few parts. This designing exclusively for 3D printers has
been termed Digital Manufacturing. KOR EcoLogic expects to
manufacture these parts in a “factory of the future” that houses
many 3D printers, all mass producing production parts.
6/2013 – RAPID 41