1 rp+m JTEG Webinar: Manufacturing for Sustainability Tom Santelle, Director of Strategic Programs August 25, 2015

2 rp+m Brief Overview of rp+m World’s First “Full Stack” AM Products and Solutions Company Invested in the most technologically advanced additive manufacturing systems and materials Providing agnostic, expert advice on all additive manufacturing technologies Focused on materials development and process advancement Emphasis on high-temperature thermoplastics and composites, refractory metals and ceramics Bringing AM Innovation to Our Industrial Clients Materials Design Processes Software Consulting

3 rp+m rp+m - introduction rp+m is a advanced technology solutions company based on Avon Lake, OH. rp+m is the premier provider of customized AM products and innovative material solutions. rp+m was formed in 2009 out of investments from Thogus, a plastic injection molding company that specializes in the manufacture of proprietary products, custom moldings and other other plastic products. rp+m has been increasingly been called upon by corporations, federal, and private research institutions to develop advancements in the markets it serves.

4 rp+m Project: AFMC Using Additive to Create Sustainability

5 rp+m rp+m, Sustainment and the Digital Thread Recent Additive Manufacturing Study USAF / AFMC two-part study to define Additive Manufacturing Information Technology (IT) Architecture Requirements Study 1: Identified the Data Requirements to “print” parts on-demand –Identify technical data requirements to enhance TDP’s –Design and develop 3D Printing Data Packages for selected AM platforms –Develop technology demonstrations for metal and polymer parts –Develop enhanced TDP’s to include, validated engineering drawings, models process specs and AM machine files for deployment to depot facilities –Print “Control Parts” on DMLS and FDM platforms Study 2: Validate results of Study 1 and explore impacts to USAF IT Architecture

6 rp+m Project Partners US Air Force Material Command – Define project requirements / scope DDC-IT Services – Document data model requirements Defense Logistics Agency – Mission Impaired Capability Awaiting Parts (MICAP) rp+m – Identify AM platforms, develop enhanced TDP’s, manufacture control parts, validate parts

7 rp+m rp+m Technical Tasks and Activities 1.Collaborated with DLA / AFMC to down-selected USAF parts for study 2.Developed manufacturing / validation drawings 3.Developed CAD models and toolpath files 4.Developed print build files for FDM and DMLS platforms 5.Printed FDM and DML control parts 6.Developed process specifications for remote printing 7.Developed post processing specifications 8.Assembled a final print package for digital delivery

8 rp+m Project Workflow Model Study 1

9 rp+m Phase I Part Selection Criteria Parts for relevant data requirements definition and validation Parts for non-flight, non-structural part replacement use cases Parts that represent both metal and polymer materials Analysis did not include fit-for-use analysis, design and testing

10 rp+m Parts Selection Criteria (cont.) MJ-1B Bomb Lift: centering lever –Need: 48/yr Cost: $38.42 Prod Time: 277 days –Material (orig.): C-1020 steel –Material (AM): MS-1 steel Generator: tow latch –Need: 55/yr Cost: $72.37 Prod Time: 100 days –Material (orig.): ductile iron –Material (AM): MS-1 steel

11 rp+m Parts Selection Criteria (cont.) Chart Holder: End Cap –Need: 19/yr Cost: $28.57 Prod Time: 92 days –Material (orig.): ABS M30 Black –Material (AM): ABS M30 Black Surrogate: Air Duct –Material (AM): ABS M30 Black

12 rp+m Data Requirements 3D Print Data Package –Five components are required to print-on-demand –Four optional components provide context and can help address unexpected problems at print-time 3D Print Package Data Reference Model (DRM): managed product data –3D print package Logical Model and attribute definitions –3D print package-to-Product Lifecycle Management (PLMi) DRM mapping Enhanced Technical Data Package (TDP) (MIL-STD-31000A): acquiring and applying 3D print package

13 rp+m Data Requirements 3D Print Package Data Reference Model (DRM): managed product data –Logical Model and attribute definitions –Product Lifecycle Management (PLMi) DRM mapping –Technical Data Package (TDP) (MIL-STD-31000A)

14 rp+m 3D Print Package DRM 3D Print Package -PLM mapping –PLM organizes data in Information Assets (IAs) –3DPDP is part of the PLI IA –Drawings/models component maps to the Drawings-Geometry IA –Other components map to PLI Engineering Data Lists (EDL) IA

15 rp+m 3DPDP-TDP Mapping 3D Print Package is a subset of the MIL-STD-31000A Technical Data Package (TDP) –Production Level (Milestone C) –TDP Elements addressed in the 3D Print Package Product drawings/models/associated lists –TDP Elements not addressed in the 3D Print Package Special Inspection Equipment drawings/models/lists Special Tooling drawings/models/lists Critical Manufacturing Processes Specifications Software documentation Special Packaging Instructions drawings/models/lists Quality Assurance Provisions

16 rp+m Summary Identified data requirements to remotely 3D Print parts Designed and developed digital print data packages Printed Control Parts Delivered Additive Manufacturing Data Requirements Report Identified and defined the 3DPDP Provided the print “code” and instructions to print a part on demand Identified 3DPDP data management and use instruments Defined the 3DPDP DRM and mapped to the PLMi DRM Mapped the 3DPDP components to the MIL-STD-31000A TDP and DI-SESS E Data Item Description Data requirements validation and IT Architecture analysis efforts needed to complete study objectives

17 rp+m Contact us! Tom Santelle, Director of Strategic Programs Tracy Albers, Ph.D. President and CTO

18 rp+m Q&A