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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
1
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?
2Making Information Dominance a Reality Through Proven C4ISR Support 2Distribution A: Approved for public release, Distribution unlimited 2
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
AN /FPN-63(V)Precision
Approach Radar
3Making Information Dominance a Reality Through Proven C4ISR Support 3Distribution A: Approved for public release, Distribution unlimited 3
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
AN /FPN-63(V)Precision
Approach Radar
4Making Information Dominance a Reality Through Proven C4ISR Support 4Distribution A: Approved for public release, Distribution unlimited 4
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
AN /FPN-63(V)Precision
Approach Radar
5Making Information Dominance a Reality Through Proven C4ISR Support 5Distribution A: Approved for public release, Distribution unlimited 5
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
Distribution Statement F: Further dissemination only as directed by CO/ED, SPAWAR Systems Center Pacific, San Diego, CA 92152-5001Dept 40 Review12/FEB/2013
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.
Making Information Dominance a Reality Through Proven C4ISR Support 7Making Information Dominance a Reality Through Proven C4ISR Support 7Distribution A: Approved for public release, Distribution unlimited 7
Distribution Statement F: Further dissemination only as directed by CO/ED, SPAWAR Systems Center Pacific, San Diego, CA 92152-5001Dept 40 Review12/FEB/2013
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
8Making Information Dominance a Reality Through Proven C4ISR Support 8Making Information Dominance a Reality Through Proven C4ISR Support 8Distribution A: Approved for public release, Distribution unlimited
Distribution Statement F: Further dissemination only as directed by CO/ED, SPAWAR Systems Center Pacific, San Diego, CA 92152-5001Dept 40 Review12/FEB/2013
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
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
Case Study
Single Point of Failure OEM Unsupported,
Obsolete Eletro-Mechanical Assembly
10Making Information Dominance a Reality Through Proven C4ISR Support 10Making Information Dominance a Reality Through Proven C4ISR Support 10Distribution A: Approved for public release, Distribution unlimited
Servo Data Potentiometer
10
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.
11
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
ScanMeasurement to fractional
thousandths of an inch
12Making Information Dominance a Reality Through Proven C4ISR Support 12Making Information Dominance a Reality Through Proven C4ISR Support 12Distribution A: Approved for public release, Distribution unlimited 12
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
Scanning Tools
13Making Information Dominance a Reality Through Proven C4ISR Support 13Making Information Dominance a Reality Through Proven C4ISR Support 13Distribution A: Approved for public release, Distribution unlimited 13
Distribution Statement F: Further dissemination only as directed by CO/ED, SPAWAR Systems Center Pacific, San Diego, CA 92152-5001Dept 40 Review12/FEB/2013
How it works The Scan Arm Laser “paints” the object to be replicated.
14Making Information Dominance a Reality Through Proven C4ISR Support 14Making Information Dominance a Reality Through Proven C4ISR Support 14Distribution A: Approved for public release, Distribution unlimited 14
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
Multiple laser scans are overlaid to make a complete picture of the object.
15Making Information Dominance a Reality Through Proven C4ISR Support 15Making Information Dominance a Reality Through Proven C4ISR Support 15Distribution A: Approved for public release, Distribution unlimited 15
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
CADComputer Aided Design
16Making Information Dominance a Reality Through Proven C4ISR Support 16Making Information Dominance a Reality Through Proven C4ISR Support 16Distribution A: Approved for public release, Distribution unlimited 16
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
Scans are transformed into “regions” for geometric extraction.
17Making Information Dominance a Reality Through Proven C4ISR Support 17Making Information Dominance a Reality Through Proven C4ISR Support 17Distribution A: Approved for public release, Distribution unlimited 17
Distribution Statement F: Further dissemination only as directed by CO/ED, SPAWAR Systems Center Pacific, San Diego, CA 92152-5001Dept 40 Review12/FEB/2013
Geometric primitives are extracted to a CAD environment.
18Making Information Dominance a Reality Through Proven C4ISR Support 18Making Information Dominance a Reality Through Proven C4ISR Support 18Distribution A: Approved for public release, Distribution unlimited 18
Distribution Statement F: Further dissemination only as directed by CO/ED, SPAWAR Systems Center Pacific, San Diego, CA 92152-5001Dept 40 Review12/FEB/2013
Primitives are “built up” to make the complex shapes of the object in the CAD environment.
19Making Information Dominance a Reality Through Proven C4ISR Support 19Making Information Dominance a Reality Through Proven C4ISR Support 19Distribution A: Approved for public release, Distribution unlimited 19
Distribution Statement F: Further dissemination only as directed by CO/ED, SPAWAR Systems Center Pacific, San Diego, CA 92152-5001Dept 40 Review12/FEB/2013
Primitives are “built up” to make the complex shapes of the object in the CAD environment.
20Making Information Dominance a Reality Through Proven C4ISR Support 20Making Information Dominance a Reality Through Proven C4ISR Support 20Distribution A: Approved for public release, Distribution unlimited 20
Distribution Statement F: Further dissemination only as directed by CO/ED, SPAWAR Systems Center Pacific, San Diego, CA 92152-5001Dept 40 Review12/FEB/2013
The obsolete assembly is used to fabricate a modern assembly in the CAD environment.
Obsolete
Modern
21Making Information Dominance a Reality Through Proven C4ISR Support 21Making Information Dominance a Reality Through Proven C4ISR Support 21Distribution A: Approved for public release, Distribution unlimited 21
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
FABAdditive Manufacturing
22Making Information Dominance a Reality Through Proven C4ISR Support 22Making Information Dominance a Reality Through Proven C4ISR Support 22Distribution A: Approved for public release, Distribution unlimited 22
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
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
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
Documentation
Assembly Instructions, Field Change Bulletins,Installation Guides, etc.
24Making Information Dominance a Reality Through Proven C4ISR Support 24Making Information Dominance a Reality Through Proven C4ISR Support 24Distribution A: Approved for public release, Distribution unlimited
CAD Data Leveraged for Configuration Management.
24
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
Case Study
Single Point of Failure OEM Unsupported,
Obsolete Actuator Assembly
25Making Information Dominance a Reality Through Proven C4ISR Support 25Making Information Dominance a Reality Through Proven C4ISR Support 25Distribution A: Approved for public release, Distribution unlimited
Actuator Motor Replacement
25
Distribution Statement F: Further dissemination only as directed by CO/ED, SPAWAR Systems Center Pacific, San Diego, CA 92152-5001Dept 40 Review12/FEB/2013
The old $5000 obsolete actuator is shown here with a sand cast rear pivot point bracket.
Making Information Dominance a Reality Through Proven C4ISR Support 26Making Information Dominance a Reality Through Proven C4ISR Support 26Distribution A: Approved for public release, Distribution unlimited 26
Distribution Statement F: Further dissemination only as directed by CO/ED, SPAWAR Systems Center Pacific, San Diego, CA 92152-5001Dept 40 Review12/FEB/2013
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.
Making Information Dominance a Reality Through Proven C4ISR Support 27Making Information Dominance a Reality Through Proven C4ISR Support 27Distribution A: Approved for public release, Distribution unlimited 27
Distribution Statement F: Further dissemination only as directed by CO/ED, SPAWAR Systems Center Pacific, San Diego, CA 92152-5001Dept 40 Review12/FEB/2013
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
28Making Information Dominance a Reality Through Proven C4ISR Support 28Making Information Dominance a Reality Through Proven C4ISR Support 28Distribution A: Approved for public release, Distribution unlimited
GeoMagicDesign X
28
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
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
29
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 30Making Information Dominance a Reality Through Proven C4ISR Support 30Making Information Dominance a Reality Through Proven C4ISR Support 30Distribution A: Approved for public release, Distribution unlimited
Obsolete
Modern Replacement
E-CAD solutions for modernization of obsolete PC card assemblies.
30
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
Case Study
Creation of 3D CAD Models of Legacy Shore
Facilities, Shelter Facilities, and Vessles
31Making Information Dominance a Reality Through Proven C4ISR Support 31Making Information Dominance a Reality Through Proven C4ISR Support 31Distribution A: Approved for public release, Distribution unlimited
Scanning of Macro-Level Constructs
31
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
The process can be performed on large systems
Engineering drawings made from these show integration of new systems
Scan
Photo
32
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
Backup
Full Shelter System Scan
33
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
Case Study
Modernization of Systems;
Addition of Walkway to Legacy Shelter
34Making Information Dominance a Reality Through Proven C4ISR Support 34Making Information Dominance a Reality Through Proven C4ISR Support 34Distribution A: Approved for public release, Distribution unlimited
Design Validation through Simulation
34
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
Simulation
35Making Information Dominance a Reality Through Proven C4ISR Support 35Making Information Dominance a Reality Through Proven C4ISR Support 35Distribution A: Approved for public release, Distribution unlimited
Design integrity is validated before fabrication.
35
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 36Making Information Dominance a Reality Through Proven C4ISR Support 36Making Information Dominance a Reality Through Proven C4ISR Support 36Distribution A: Approved for public release, Distribution unlimited
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
36
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 37Making Information Dominance a Reality Through Proven C4ISR Support 37Making Information Dominance a Reality Through Proven C4ISR Support 37Distribution A: Approved for public release, Distribution unlimited
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.
37
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
ProcessInput / Throughput / Output
38Making Information Dominance a Reality Through Proven C4ISR Support 38Making Information Dominance a Reality Through Proven C4ISR Support 38Distribution A: Approved for public release, Distribution unlimited 38
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
Arm / Area
Scanner
FAROScene
Geo Magic
Design X
Solid Works
CAD
“BluePrints”
Printer Driver
3D Printer
Software
SolidWorksComposer
Output Products
Hardware
Key
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
Archive
Network
Global Partners
Translation by Software 10 hours
Translation by Draftsman 30days
I/O Data
Translation by Software 5 hours Part
Part
Fabrication Engineering Utilizing Reverse Engineering and Additive Manufacturing
SCAN
FAB
CAD
DOCS
39Making Information Dominance a Reality Through Proven C4ISR Support 39Making Information Dominance a Reality Through Proven C4ISR Support 39Distribution A: Approved for public release, Distribution unlimited 39
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
Coming in January 2014RESTORE LaboratoryReverse Engineering; Science and Technology for Naval Base Point Loma Obsolescence, Repair, and Evaluation Laboratory SSC-PAC, OT2, Rm1864
40Making Information Dominance a Reality Through Proven C4ISR Support 40Making Information Dominance a Reality Through Proven C4ISR Support 40Distribution A: Approved for public release, Distribution unlimited 40
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
Questions?
41Making Information Dominance a Reality Through Proven C4ISR Support 41Making Information Dominance a Reality Through Proven C4ISR Support 41Distribution A: Approved for public release, Distribution unlimited 41
Distribution Statement F: Further dissemination only as directed by CO/ED, SPAWAR Systems Center Pacific, San Diego, CA 92152-5001Dept 40 Review12/FEB/2013 42