Design World

  • Home
  • Technologies
    • 3D CAD
    • Electronics • electrical
    • Fastening & Joining
    • Factory automation
    • Linear Motion
    • Motion Control
    • Test & Measurement
    • Sensors
    • Fluid power
  • Learn
    • Ebooks / Tech Tips
    • Engineering Week
    • Future of Design Engineering
    • MC² Motion Control Classrooms
    • Podcasts
    • Videos
    • Webinars
  • LEAP AWARDS
  • Leadership
    • 2022 Voting
    • 2021 Winners
  • Design Guide Library
  • Resources
    • 3D Cad Models
      • PARTsolutions
      • TraceParts
    • Digital Issues
      • Design World
      • EE World
    • Women in Engineering
  • Supplier Listings

Military Easily Moves from Design to Manufacture with FDM

By Leslie Langnau | August 10, 2010

Share

Based at Sheppard Air Force Base, Wichita Falls, Tex., the Trainer Development Flight (TDF) is a facility that designs, develops, and manufactures trainers and training aids for the Air Force and all branches of the Department of Defense (DoD) as required. These items are used in numerous training environments, including avionics, weapons and fuel systems, medical readiness, HVAC, and telecommunications systems.

The trainers and training aids may be either original products or replicas of existing ones, depending on the need. Some devices are not required to be working units, so it usually isn’t cost-efficient to purchase the actual item. For most training applications, it’s more economical to train students on replicas, instead of the often extremely expensive equipment.

military-fdm uav

For the Department of Defense, the TDF designs and builds “trainers” and “training aids” such as UAV replicas to train students.

To make the replicas, the TDF often uses direct digital manufacturing. It employs four fused deposition modeling (FDM) additive fabrication machines in a central location with AFSO 21 (Lean) processes incorporated into the overall process.

“Because most of our projects are either one-of-a-kind or very low volume, conventional methods are very expensive,” said Mitchell Weatherly, Chief of the TDF. “Only about 10 percent of our work is for prototyping, and 90 percent is prod-uction. With FDM, the investment is up front, not ongoing. Plus, the process is environmentally safe and 100% ‘green’ with zero waste.”

uav-antenna-fdm

Antenna and other components being manufactured by a Fortus FDM machine.

The TDF designed and manu-factured an exact replica of an unmanned aerial vehicle (UAV) or “drone” for training repair technicians. Many of the internal and external components were built on the FDM machines. These components included most of the body as well as several cowlings, propellers, and antennas. They also purchased a number of real UAV components from the OEM.

For the production of the UAV’s large antenna alone, the FDM machines did the job in about one-tenth the time it would normally have taken with conventional methods, and it delivered an ROI of over $12,000.

The savings go beyond time, though. For the antenna, it would have taken an outsourced machine shop up to 20 days to produce the part, where it took only two days using FDM — but only 15 to 20 minutes of labor. For the entire UAV project, total time saved was more than three years in some areas. Total savings on this project, and others over the last four years, is $800,000.

fortus-fdm-uav-components

With direct digital manufacturing, the TDF can produce batches of components.

“Major advantages to the FDM system include its speed over other processes or alternative build methods, the versatility of FDM versus injection molding, and the ability to run multiple parts simultaneously through the system,” said Weatherly.

“Additional capabilities include the ability to design based on function needs instead of manufacturing constraints, and the ability to implement design changes immediately and at minimal costs,” continued Weatherly. “The versatility to manufacture any item coupled with zero hazardous waste is one of the greatest advantages to the Air Force. The FDM-based machines have been used for a number of trainer projects, which have tight budgets. We have also used the FDM process for research and development for our airmen and soldiers to be able to train like we fight.

“For our first FDM machine purchase, we projected ROI in 4 years, but it took only 18 months,” Weatherly said. “For our second FDM machine purchase we saw ROI in only 9 months. You will never get away from conventional methods and highly skilled technicians, but you can give them the proper tools and new technology that can make their job easier and competitive. Since 2004, when we purchased our first of four machines, the FDM process has saved the government over $3.8 million to date with an expected 10-to-15-year savings of over $15 million.“

Fortus 3D Production Systems,Stratasys Inc.
www.fortus.com


Filed Under: Aerospace + defense, Digital manufacturing, Simulation, Software
Tagged With: fortus
 

Tell Us What You Think!

Related Articles Read More >

Ontic acquires Servotek and Westcon product lines from Marsh Bellofram
Flexible rotary shafts support thrust reverser on 150 LEAP 1-A turbofan engines
Drone-mounted inspection breaks barriers for F-35
TriStar, a misunderstood failure of design

DESIGN GUIDE LIBRARY

“motion

Enews Sign Up

Motion Control Classroom

Design World Digital Edition

cover

Browse the most current issue of Design World and back issues in an easy to use high quality format. Clip, share and download with the leading design engineering magazine today.

EDABoard the Forum for Electronics

Top global problem solving EE forum covering Microcontrollers, DSP, Networking, Analog and Digital Design, RF, Power Electronics, PCB Routing and much more

EDABoard: Forum for electronics

Sponsored Content

  • Global supply needs drive increased manufacturing footprint development
  • How to Increase Rotational Capacity for a Retaining Ring
  • Cordis high resolution electronic proportional pressure controls
  • WAGO’s custom designed interface wiring system making industrial applications easier
  • 10 Reasons to Specify Valve Manifolds
  • Case study: How a 3D-printed tool saved thousands of hours and dollars

Design World Podcasts

May 17, 2022
Another view on additive and the aerospace industry
See More >
Engineering Exchange

The Engineering Exchange is a global educational networking community for engineers.

Connect, share, and learn today »

Design World
  • Advertising
  • About us
  • Contact
  • Manage your Design World Subscription
  • Subscribe
  • Design World Digital Network
  • Engineering White Papers
  • LEAP AWARDS

Copyright © 2022 WTWH Media LLC. All Rights Reserved. The material on this site may not be reproduced, distributed, transmitted, cached or otherwise used, except with the prior written permission of WTWH Media
Privacy Policy | Advertising | About Us

Search Design World

  • Home
  • Technologies
    • 3D CAD
    • Electronics • electrical
    • Fastening & Joining
    • Factory automation
    • Linear Motion
    • Motion Control
    • Test & Measurement
    • Sensors
    • Fluid power
  • Learn
    • Ebooks / Tech Tips
    • Engineering Week
    • Future of Design Engineering
    • MC² Motion Control Classrooms
    • Podcasts
    • Videos
    • Webinars
  • LEAP AWARDS
  • Leadership
    • 2022 Voting
    • 2021 Winners
  • Design Guide Library
  • Resources
    • 3D Cad Models
      • PARTsolutions
      • TraceParts
    • Digital Issues
      • Design World
      • EE World
    • Women in Engineering
  • Supplier Listings