Direct Digital Manufacturing of Integrated Naval Systems Using Ultrasonic Consolidation, Support Material Deposition and Direct Write Technologies

Abstract

This project enabled the integration of ultrasonic consolidation, direct write dispensing, and material deposition technologies into a manufacturing workcell capable of fabricating advanced, integrated Naval-relevant structures. The workcell was shown to be capable of spatial composition control and complex internal geometries - including embedded electronics, thermal management, reinforcement fibers and other features - along with the resolution, scalability, repeatability, dimensional accuracy and surface finish of milling, all within an integrated Direct Digital Manufacturing (DDM) workcell. A one-year extension led to the development of a computational modeling infrastructure for ultrasonic consolidation that has revolutionized the prediction of the effects of process parameter variations on bonding, microstructure and mechanical properties of parts made using ultrasonic consolidation.

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Document Details

Document Type
Technical Report
Publication Date
Feb 17, 2012
Accession Number
ADA558190

Entities

People

  • Brent Stucker
  • Ryan B. Wicker

Organizations

  • Utah State University

Tags

Communities of Interest

  • Advanced Electronics
  • Cyber

DTIC Thesaurus Topics

  • Additive Manufacturing
  • Assembly
  • Crystal Lattices
  • Department Of Defense
  • Embedded Systems
  • Engineering
  • Fabrication
  • Fused Deposition Modeling
  • Geometry
  • Manufacturing
  • Manufacturing Engineering
  • Materials
  • Materials Processing
  • Mechanical Properties
  • Plastic Properties
  • Stereolithography
  • Temperature Control

Fields of Study

  • Materials science

Readers

  • Integrated Circuit Design and Technology.
  • Reinforced Composite Materials
  • Robotics and Automation.

Technology Areas

  • Microelectronics