Direct Part Manufacturing (DPM) for Nonstructural Components

As rapid prototyping methodology evolves into rapid manufacturing reality, successful application hinges increasingly upon the available material selection and corresponding optimized process parameters. Research is being completed specific to the laser sintering process to develop next generation high temperature materials and hardware that will satisfy or exceed the increasing demands of industry. Obstacles to the integration of high temperature polymers and the laser sintering process include hardware limitations and material/process interactions and development.  Current laser sintering machines typically require heavy modification to process at elevated temperatures.  Additionally, the requisite materials are sometimes hindered by process compatibility   The presentation will focus upon hardware advancements made with EOS beta version P700 high temperature equipment (up to 350° C) and the parallel material development effort that has been underway for over two years.  Specific attention will be given to pitfalls encountered during development and on optimization results.  Both dimensional and mechanical property results will be shown to support the case. BENEFITS: Part candidates have been identified for the F-35 Joint Strike Fighter program.  Successful qualification of a high temperature thermoplastic may yield as many as 1200 piece parts per airframe in various clips, brackets and air ducts.  Cost savings at the non recurring level and recurring level are significant with the current cost model projections.