On-Demand Repair Part Manufacturing with MRAM

Mainstream Engineering will adapt our existing multi-material robotic additive manufacturing system (MRAM) for the end-to-end fabrication of cooling fans and other highly-complex replacement parts on-demand for Army platforms. Specifically, Mainstream will supplement the MRAM to create and store complete manufacturing files for the MRAM to automatically print, machine, and assemble complex Class IX repair parts. This database will enable Mainstream, the Army, or OEMs to add parts with complete part designs, optimized material profiles, validated machining parameters, and other key part attributes to allow on-site soldiers to simply select a part and have the MRAM begin manufacturing – no knowledge of 3D printing, machining, or part assembly required. Further, Mainstream will optimize the underlying control system for ease of use and create a comprehensive user and simplified training guide to enable any user of the system to manufacture any part on-demand, whether it is in the database yet or not. Finally, Mainstream will supplement the MRAM with a computer vision camera for post-process dimensional scanning to ensure parts manufactured meet the required tolerances. The MRAM is a 6-degree-of-freedom robotic arm-based manufacturing system that is designed to be an all-in-one mobile factory. Unlike traditional 3D printers, the MRAM features a tool changer and a custom-built control system that allows it to automatically change to, and control, up to 52 unique tools in a single program. This means that the MRAM can print thermoplastics, thermosets, ceramics, or metal materials, in addition to being able to switch to a gripper to pick-and-place components, a spindle to post-process machine parts, a computer vision camera to dimensionally scan finished parts, and more. Further, we have developed a patent-pending continuous strand embedding mechanism that may be used in this proposed effort to further strength printed parts with continuous fibers.