3D SCAN-to-CAD-to-SIM-to-FAB Applied Reverse Engineering · Additive Manufacturing as Part of...

Distribution Statement F: Further dissemination only as directed by CO/ED, SPAWAR Systems Center Pacific, San Diego, CA 92152-5001Dept 40 Review12/FEB/2013

Stephen Cox, CMfgE, BSMath, MSEng ECEChief Engineer, US Navy, SSC-PAC, 41110

Principle Investigator, NISE

Making Information Dominance a Reality Through Proven C4ISR Support

3D SCAN-to-CAD-to-SIM-to-FAB

Applied Reverse Engineering

1Distribution A: Approved for public release, Distribution unlimited

Application of 3D Engineering and Additive Manufacturing to the US Navy

Distribution Statement F: Further dissemination only as directed by CO/ED, SPAWAR Systems Center Pacific, San Diego, CA 92152-5001Dept 40 Review12/FEB/2013 Making Information Dominance a Reality Through Proven C4ISR Support

Sure, it’s old, but it still works great. Can ya’ fix it?

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AN /FPN-63(V)Precision

Approach Radar

Distribution Statement F: Further dissemination only as directed by CO/ED, SPAWAR Systems Center Pacific, San Diego, CA 92152-5001Dept 40 Review12/FEB/2013 Making Information Dominance a Reality Through Proven C4ISR Support 6Making Information Dominance a Reality Through Proven C4ISR Support 6Distribution A: Approved for public release, Distribution unlimited 6

Current Sustainment Methods

1) Contract with the last civilian/military support authority.Problem: Often the last “expert” is Retired or No Longer Available.

2) Contract with a new company for a form, fit, and function replacement.Problem: Urgent Need and Small Quantities often discourage industry.

3) Cut cardboard template to fit application, then fabricate from template.Problem: No Configuration Management, or Traceability to Requirements.

4) Find obsolete parts in “Military Surplus” or specialty “Vintage Part” vendors.Problem: Surplus usually used/aged parts, vintage parts are sold at a premium.

5) For installs, “field fit” using any method available.Problem: Field fit is the most expensive/least controlled method used.

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Reverse Engineering: to study or analyze, a device in order to learn details of design, construction, and operation, to produce a functional copy, or an improved version.

Navy Reverse Engineering is performed when;1) The Warfighter has an urgent need for the solution.2) A form, fit, and function GOTS/COTS replacement is not available.3) Support for small lots of parts are not profitable for industry.4) Parts require prohibitive NRE Fee.5) OEM is no longer in business.6) OEM no longer supports product or product line.7) Obsolete part data rights are not obtainable.8) No “Blueprints”, plans, or TDP are available.

NRE : Non-Recurring Engineering GOTS : Government Off-the-ShelfCOTS : Commercial Off-the-ShelfOEM : Original Equipment ManufacturerTDP : Technical Data Package

for public release, Distribution unlimited

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Applied Reverse Engineering1) Document Condition (SCAN)

2) Design a Solution (CAD)

3) Test the Solution in Simulated Environment (SIM)

4) Implement the Solution (FAB)

5) Manage the Solutions (PROCESS)Distribution A: Approved for public release, Distribution unlimited 9

Case Study

Single Point of Failure OEM Unsupported,

Obsolete Eletro-Mechanical Assembly

Servo Data Potentiometer

Distribution Statement F: Further dissemination only as directed by CO/ED, SPAWAR Systems Center Pacific, San Diego, CA 92152-5001Dept 40 Review12/FEB/2013 Making Information Dominance a Reality Through Proven C4ISR Support 11Making Information Dominance a Reality Through Proven C4ISR Support 11Making Information Dominance a Reality Through Proven C4ISR Support 11Distribution A: Approved for public release, Distribution unlimited

This is a servo data potentiometer,or SDP. It is a positioning reportingdevice for the which takes a

mechanical input from a physical connection with the radar antenna and creates an electrical signal which shows the operator on a display screen where the antenna is pointed in space. It is a single point of failure, meaning that if this device malfunctions, the entire radar is down. There are 40+ such radar systems world wide. Each radar has two of these SDPs. The last one was manufactured in 1952.

ScanMeasurement to fractional

thousandths of an inch

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Scanning Tools

How it works The Scan Arm Laser “paints” the object to be replicated.

Multiple laser scans are overlaid to make a complete picture of the object.

CADComputer Aided Design

Scans are transformed into “regions” for geometric extraction.

Geometric primitives are extracted to a CAD environment.

Primitives are “built up” to make the complex shapes of the object in the CAD environment.

The obsolete assembly is used to fabricate a modern assembly in the CAD environment.

Obsolete

Modern

FABAdditive Manufacturing

Modern Solution Realized

ModernCAD Solution Envisioned

Additively Manufactured Parts transform the CAD into a Reality

Fast , Cheap, & Lot sizes of One 23Making Information Dominance a Reality Through Proven C4ISR Support 23Making Information Dominance a Reality Through Proven C4ISR Support 23Distribution A: Approved for public release, Distribution unlimited 23

Documentation

Assembly Instructions, Field Change Bulletins,Installation Guides, etc.

CAD Data Leveraged for Configuration Management.

Case Study

Single Point of Failure OEM Unsupported,

Obsolete Actuator Assembly

Actuator Motor Replacement

The old $5000 obsolete actuator is shown here with a sand cast rear pivot point bracket.

A new $250 actuator fits and drives the reflector. Being slightly longer than the original obsolete actuator the rear bracket’s pivot point is moved back, while the base still uses the existing chassis attachment points in the floor.

Additive Manufacturing as Part of Reverse Engineering SPAWARSYSCEN PACIFIC, San Diego

Specific ApplicationsObsolete components are replaced with Commercial-off-the-Shelf (COTS) components using AM to make new bracket and mechanical attachments. In this case, an obsolete, $5000.00 actuator is replaced by a COTS, $250.00 actuator of a slightly different size, which is retrofit into the assembly environment using AM parts. Developmental applications are prototypes, fast-turns, "get-home" and "single-use" parts (NAVAIR, Fleet and Carrier Sponsors), specialized tooling, and mold making (for carbon fiber parts).

Impacts/Benefits to WarfighterRapid and repeatable process of obsolescent management engineering from present state capture to, design, test, prototype, build, and document for fabrication at point-of-use, worldwide.

COTS Actuator $250 AM is utilized as part of SSC PACIFC C4ISR Applied Reverse Engineering process in obsolescence management. The process begins with a laser scan of the design environment producing a “cloud” of data, used by CAD software modeling the environment. Model COTS parts are placed in the environment and new custom parts are designed to make the COTS part a form-fit-function replacement solution. These new parts may be realized using AM with files which may be shared worldwide. Logistics instructions and support drawing are leveraged from CAD data, residing in an Enterprise Manager, using meta-data to update configuration management.

Retrofitted with AM Parts

Obsolete Actuator $5,000

GeoMagicDesign X

Case Study

Single Point of Failure OEM Unsupported, Obsolete PC Card

Electronics Module Assembly 29Making Information Dominance a Reality Through Proven C4ISR Support 29Making Information Dominance a Reality Through Proven C4ISR Support 29Distribution A: Approved for public release, Distribution unlimited

PC Card Modernization

Obsolete

Modern Replacement

E-CAD solutions for modernization of obsolete PC card assemblies.

Case Study

Creation of 3D CAD Models of Legacy Shore

Facilities, Shelter Facilities, and Vessles

Scanning of Macro-Level Constructs

The process can be performed on large systems

Engineering drawings made from these show integration of new systems

Backup

Full Shelter System Scan

Case Study

Modernization of Systems;

Addition of Walkway to Legacy Shelter

Design Validation through Simulation

Simulation

Design integrity is validated before fabrication.

A 3D CAD model of the shelter is made from a Laser Scan. The model is modernized with the addition of a live weight bearing walkway.

Legacy Shelter

3D CAD Model

Simulated Performance Model

Design integrity is validated before fabrication. The 3D CAD model realized from the laser scan assures fit and the simulation assures function.

ProcessInput / Throughput / Output

Arm / Area

Scanner

FAROScene

Geo Magic

Design X

Solid Works

“BluePrints”

Printer Driver

3D Printer

Software

SolidWorksComposer

Output Products

Hardware

Enterprise Project Data Management

Input Data

Good Part

Bad /Broken Part

Missing Part

2D CAD Post 2000

2D CAD Pre 2000

3D CAD Post 2000

Process Data

Process Management

Instructions

Animations

Machine Cell Fabrication

Additive Manufacturing

Paper / Ideas

3D SCAN-to-CAD-to-SIM-to-FAB Applied Reverse Engineering · Additive Manufacturing as Part of...

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