Rapid reverse engineering and validation for Air Force applications

ABSTRACT: Advratech will work with the University of Dayton Research Institute and Lockheed Martin Corp. to develop a novel reverse engineering process for the Air Force sustainment Center. The key technologies include 3D scanners (with 30 um accuracy), additive manufacturing (AM) software with automatic support structure development, a selective laser melting (SLM) testbed, a subtractive micromachining laser, and a laser-line profilometer. By integrating these technologies into a single process we will be able to reverse engineer parts with only a single software handoff, demonstrate in situ dimensional validation of the part, as well as post-build dimensional validation. 3D scanning and build preparation take only a few hours combined, so every part will be reverse engineered and built within 5 days. The most novel aspect of this project is modifying our SLM testbed by adding a subtractive micromachining laser to perform in-process micromachining. This will allow us to build components with more accurate dimensional accuracy, and importantly, with smooth surface finish that is required of many Air Force components. Therefore, we can adjust this build process to meet the end-use requirements of any single part.; BENEFIT: The project will create a new process that will facilitate rapid reverse engineering of components of interest to the Air Force sustainment center (AFSC). Benefits include: 1) Easy 3D scanning of components with no available CAD file. 2) Reverse engineering and correction of damaged and worn out parts. 3) In-process dimensional validation of areas embedded in the part that cannot be scanned post-build 4) Post-build dimensional validation to ensure the part meets geometric requirements. 5) Parts can be built with smooth surface finish, rough surface finish, or somewhere in between to meet end-use requirements. 6) Short turnaround time will enhance AFSC efficiency. Future research on this process could also enable a unique form of closed-loop feedback control, thus improving process reliability and further enhancing AFSC capability. Potential commercial applications of this process are vast, as they are for any additive manufacturing advancement. Initial customers of interest will include aerospace prime contractors such as Lockheed Martin Corp. (LMCO), Boeing, or Pratt & Whitney. LMCO sees potential benefits to several of their current Air Force programs, including the F-35 Joint Strike Fighter, B-2,C-130, and several others. In fact, because of their strong interest in commercializing this technology they have joined the project team as a subcontractor. Advratech also currently has strong relationship with NASA, where this technology could also be useful for reverse engineering and producing components for NASA platforms. We also envision interest from industries outside of aerospace, such as the automotive industry.