Additive Manufacturing of Masking to Support Turbine Engine Sustainment

ABSTRACT: Protective masking of part surfaces is critical during the component repair process.Whether using Arc wire, Plasma spray, HVOF, cold spray, grit blasting or tumbling the operator needs to be able to define the repair area on the component.Traditionally this has been done using plasma taping which is a very labor intensive process.Traditional cast masking can change the way a shop operates.In addition to the time reduction, cast masking provides a more repeatable process since a mask with consistent geometry does not rely on an operator taping the components.The manufacturing of cast masking is a time consuming process.Additive printer technology has enhanced the ability to provide customers with better traditional cast masking however customers are requesting directly printed masks.The ability to print a complex mask such as an airfoil or dovetail that a customer can directly apply to a component will significantly reduce the lead-time for masking development.Current lead-times for development masks are measured in weeks not days.The ability to send a file to a 3D printer to print the finished mask is a benefit that every customer wants.; BENEFIT: Masking is a broad category consisting of specialized urethane and silicone masks of various shore hardness.The existing masking products are custom cast urethane and silicone molds. Currently there is not a lot of 3D printed masking available that fits a specific customer application.Occasionally 3D printed parts meet niche masking needs but on an extremely limited basis.Many customers have expressed an interest in printed masking and would support product development and in shop testing.Additional applications exist beyond aerospace in multiple industries including automotive, medical and power generation.