Improved Extrusion and Milling Techniques

The overall goal of our Phase I project is to demonstrate the feasibility of innovative high performance machining (HPM) enabled by physics-based modeling the Navy needs to manufacture FlexTech in a mass produced, affordable, high tolerance manner. The anticipated benefits of the program are the application of HPM to aluminum machining and minimized part distortion through the managing of residual stresses resulting in reduced labor costs, cycle time and the creation of large, high tolerance parts. We will demonstrate both our innovative, scalable HPM process utilizing proprietary thermal management techniques in combination with machining modeling and our minimized part distortion method on a representative FlexTech component. Working with suppliers and manufacturers, we will identify the needs and requirements for a Phase II effort.