Improved Manufacturing Technology for Investment Casting Cores

ABSTRACT: The centerpiece of this proposed work is the application of an innovative manufacturing technology developed by Mikro Systems, Inc. (Mikro) called Tomo-Lithographic-Molding (TOMO). In recent years important breakthroughs have been realized as TOMO has been applied to the production of advanced ceramic cores for investment casting of turbine airfoils. For large IGT components, Mikro technology is currently at a high readiness level. This effort would work to adapt the advanced core success TOMO has made for large industrial gas turbine components to advanced smaller scale aerospace airfoils. This Phase II will complete a critical development phase which will address the remaining technical challenges of adapting the technology. This development is in preparation for a follow on production effort in which Mikro Systems will produce ceramic cores for complex turbine blades for an OEM"s turbine platform. These turbine blades will be delivered to a planned engine test that will demonstrate a technology readiness increase for TOMO and significant component cost reductions. BENEFIT: This effort will demonstrate Mikro"s ability to significantly compress the design-to-production time, reduce manufacturing cost, and improve product producibility/quality of aerospace turbine airfoils. Successful transition of the TOMO technology through this program will reduce system costs and improve component performance for the targeted platform. Mikro"s technology will also enable rapid program scale-up, reduce acquisition costs and improve surge production capabilities. TOMO is a dual use technology and has opportunities for commercialization in military unique, dual use, and civil aerospace turbines. Additionally, given the flexibility of the TOMO process, advancements can be developed for other turbine components increasing the positive impact and ROI of the technology. These benefits will improve turbine specific fuel consumption, improve thrust performance, and reduce emissions for turbine engines. Successful transition would present significant growth for Mikro Systems and benefit the local economy though significant job creation.