Advanced Manufacturing Technologies

In response to Defense Logistics Agencys SBIR for Advanced Manufacturing Technologies, Sentient proposes to develop a life-cycle cost optimization tool based on its DigitalClone-ComponentTM (DCC) modeling technology.This tool will enable users to better understand the tradeoffs between manufacturing cost and performance/durability of the resultant components. This is particularly attractive for low volume components produced through additive manufacturing (AM) processes, which can significantly reduce upfront tooling costs especially in support of legacy fielded weapon systems. However, qualification of AM components may require costly experimental testing to determine reliability. Sentient is proposing a tool that will allow the user to conduct these performance tests in a virtual environment, which provides upfront knowledge of expected mean time between failures. This information can then be factored into the LCC calculation along with up-front manufacturing costs. The proposed tool is equally applicable to components manufactured with traditional processes. During Phase I, Sentient will demonstrate technical feasibility of the tool through life-cycle cost analysis of an example component produced both by additive manufacturing and through traditional machining. Ground truth durability of these components will be determined through experimental testing. These results will then be compared to DCC predictions to validate the potential cost savings.