Directed Energy Deposition System for Advanced Manufacturing Research
Abstract
Objective: Enhance USMA advanced manufacturing research capabilities and enable the development of novel manufacturing processes for defense applications through acquisition of a state-of-the-art Directed Energy Deposition (DED) system. Overview: Additive manufacturing, and DED in particular, has pushed forward the frontier of manufacturability, enabling the creation of parts that cannot be made via traditional manufacturing methods. However, there is still much work to be done to mature this technology and enable the novel applications of this additive process. The acquisition of a DED system will enable USMA cadet and faculty researchers to (1) Employ DED for rapid prototyping of components with commercially available metals, (2) Create, analyze, and prove-out processes to reverse-engineer and repair legacy DoD components at the point-of-need, (3) Develop deposition parameters to create novel materials, (4) Design and process materials with functionally graded compositions due, (5) Explore convergent manufacturing processes to enable heterogenous components comprised of dissimilar materials. This system will enhance USMA s research and education efforts, and enable research that will contribute to DoD interests and advance national defense. Equipment Description: The LENS CS-250 Additive Base System is a highly advanced and versatile 3D printing solution designed for industrial-grade additive manufacturing applications. This system is equipped with an integrated LENS Print Engine, which includes a LENS laser deposition head with a 4-tip nozzle head and an interchangeable coax nozzle assembly. The system includes four powder feeders, the maximum possible in existing systems, to accommodate a wide range of materials and printing applications. Research Enabled: The acquisition of a DED system will unlock a wide range of research opportunities, enabling multiple pathways to 6.1 and 6.2 research, other DoD innovation and research, including advancing current cooperative research between DEVCOM ARL and USMA in advanced manufacturing. The research on several active programs will be accelerated by the acquisition of this machine. Specifically, the West Point Terminal Effects Project sponsored by the ARO Terminal Effects Branch Mechanical Behavior Program project will be able to print materials in-house to be studied for high-strain rate loading. The Hypersonic Convergent Manufacturing Capstone project will be able to experimentally investigate the feasibility of coprocessing dissimilar materials. Lastly, the Soldier Innovation Projects with Catalyst Pathfinder Project collaborations will be able to leverage the DED machine to rapidly prototype and test new innovations, leading to more efficient and effective solutions for soldiers in the field. The acquisition of a DED machine will enhance the quality of current research conducted at USMA, provide new opportunities for collaboration, and provide numerous opportunities for further future research in the defense industry including and beyond the areas already discussed.
Document Details
- Document Type
- DoD Grant Award
- Publication Date
- Aug 09, 2023
- Source ID
- W911NF2310337
Entities
People
- Jennifer Bennett
Organizations
- Army Contracting Command
- United States Army
- United States Military Academy