A Solid FreeForm Fabrication Process to Produce Functional Metal Parts and Tools

The supply of critical replacement parts to maintain the readiness of military units serving overseas can be a problem. Lone Peak Engineering (LPE) has identified an opportunity to develop a solid freeform fabrication (SFF) process to manufacture functional metal components. These metal components, prepared in a manner of hours from computer-generated models without hard tooling could be quickly shipped out as replacement parts to alleviate this supply problem. A fully developed system could be placed in remote locations, such as onboard ships, to provide parts on an as needed basis. This possibility could dramatically reduce the inventory of spare parts needed to maintain the Navy's ships, submarines, aircraft, and other equipment. This Phase I project will demonstrate the feasibility of using this SFF process to fabricate functional metal parts and tools from 316L stainless steel. Lone Peak will team with United Technologies Research Center (UTRC) in this Phase I project. During the Phase I project, United Technologies operating divisions will be surveyed for applications. Parts for these applications will be made during the Phase H project. Some possible applications include gears and injection molding tooling. The Phase H project will demonstrate that SFF-prepared metal parts and tools can be used in functional applications. To achieve this goal, automated production procedures will be developed. Additional metal compositions will be examined. Sintering to full density and hot isostatic pressing will be examined. Machining and finishing techniques will be developed.