Additive Manufacturing for Lightweight, Low Cost Seeker Gimbals

In 2010, CalRAM was awarded a Phase I SBIR to produce lightweight, low-cost precision seeker gimbals for high volume production that can operate in military aviation environments. Using an additive manufacturing technology based on electron beam melting (EBM), CalRAM built a near-net shape Ti-6Al-4V gimbal ring. In addition, a manufacturing cell capable of producing gimbal rings in quantities to support a production line was designed. For the Phase II program, CalRAM will work with Lockheed Martin to develop an EBM design and fabricate and test approximately 20 gimbal rings. A detailed design of the manufacturing cell will be developed along with work instructions for each work station. A manufacturing and quality plan for the production of the gimbal rings will be prepared and preproduction readiness review will be held to demonstrate the viability of the manufacturing approach. As part of this effort cost and schedule metrics will be developed to demonstrate the feasibility of meeting the cost target and delivery requirements.