Lockheed Martin - Pennsylvania State University Freshman Design Effort - LM... · –“Topology Optimization” ... • Lockheed Martin has many airborne platforms that were

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Lockheed Martin


Helping the Future

Arrive

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115,000 Employees

60,000 Scientists & Engineers

500+ U.S. Facilities

Operating in 70

Countries

Our People


Lockheed Martin

100+ Years of Accelerating Tomorrow

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Business Areas

Space

Systems

Mission Systems &

Training

Missiles & Fire

Control

Aeronautics


Partnering with customers to invent the technologies that keep them one step

ahead of the challenges on the horizon

Advanced Technologies

Human Performance

Unmanned Vehicles

Exoskeletons

Congnitive Interface

Advanced Materials

Integrated Multifuctional

Materials

Energy Storage

Nano-scale Sensors

Data Analytics

Quantum Computing

Forecasting

Cyber Security

Medical Analytics

Advanced Manufacturing

Additive Manufacturing

Digital Tapestry

Next-Gen Electronics

Information Technology

Information Management

Cloud Computing

Biometrics


Additive Manufacturing Across LMEBM® (Electron-Beam Mfg.)

DMLS® – Direct Mfg. Laser Sinter

SLS® – Selective Laser Sintered

FDM® – Filament Direct Mfg.

SLA® – Stereo Lithography

Extensive Internal Capability and Expertise


Future Opportunities

• The Value of Additive Manufacturing

– >75% span time reduction

– >50% fabrication cost savings

– >50% weight savings

– Multi-functional capabilities

• Untapped design space

– “Topology Optimization”

– Graded materials and structure

• Considerations

– Access to fabrication capability

– Development of design knowledge and capability

– Assessment of concepts and application opportunities

Build what

we can Design

Design what

we can Build

New Design Paradigm Needed for Biggest Opportunities


The Ideal Additive Manufacturing

Engineer…

• Has a ‘maker mentality’

• Challenges part/assembly paradigms

• Is very comfortable designing in ‘sprints’

• Values iterative design

• Understands when to use and when not to use AM technologies

• Is knowledgeable in many AM technologies and materials (metals and polymers)

• Recognizes that some things are best manufactured using conventional machining practices

• Explores the use of AM in both mechanical/structural and electronics applications

• Understands the equipment and basic troubleshooting


Advanced Manufacturing in

Lockheed Martin

Accelerating the Transition from the Laboratory to Production (MRL 4->7)

Manufacturing Focus Areas

Additive ManufacturingThe application of industrial 3D printing to rapid prototyping, tooling, and fully qualified products & systems.

Advanced MaterialsThe maturation of advanced metals, plastics, composites, and nanotechnology for aerospace applications and

new ventures.

Digital Tapestry for ManufacturingThe application of Model-Based Engineering, IT, visualization, intelligent machines, and mobile computing to

enhance shop floor productivity.

Next Generation ElectronicsThe maturation of trusted microelectronics, advanced packaging, and photonics to significantly reduce the Size,

Weight, Power, and Cost of embedded systems.


2016 Project Overview


Project #1Additively Manufactured Heat Exchanger

• Lockheed Martin designs and builds many computer

assemblies. These computers utilize circuit card

assemblies that consist of various electrical components

that can get very hot during a mission. Heat exchangers

are used to remove the heat and safe-guard the

components. These heat exchangers can be expensive

to produce using traditional manufacturing methods.

– Redesign an existing heat exchanger for AM

– Choose a proper AM process and material for the heat

exchanger

• Cost and build time must be taken into account

• Sample part can be built using plastic additive

technology, but differences in design between

plastic-built part and actual part should be reported

– Overall size factor must remain as-is and CCA Mating

features must remain as-is

– Internal air-flow thru geometry can change, but

surface area must remain constant.


Project #2Aircraft Bracket Reverse Engineering

• Lockheed Martin has many airborne platforms that were

designed prior to the dawn of computer aided design (CAD)

modeling. These platforms were designed and built using

two dimensional paper and pencil drawings. In order to

facilitate future development of these platforms, the historical

parts must be evaluated for dimensional accuracy and

translated into a functional CAD model.

– Use 3D scanning technology to create a solid model of an

existing bracket.

– Use traditional measurement methods (including Verniers

and Micrometers) to verify dimensions from the scanned

model.

– Create a functional CAD model and 2D drawing utilizing

solid modeling software (e.g. Solid Works, Creo, etc).

– Overlay the scanned model on the CAD model and

analyze any differences.

– Stretch Goal: Update the bracket design so that it can be

built using additive manufacturing and build a plastic AM

part.


Project #3Sensitive Payload Shock Absorber

• Lockheed Martin has several unmanned aerial vehicles (UAVs) that experience high shock loads upon landing. These UAV parts must be as lightweight as possible yet strong enough to handle the harsh landing conditions. Develop an internal member to transfer and distribute the shock loads from the tail to the elevator.

– Structure should be able to handle multiple landings

• Bending moments will be acting on the lever and fastener holes.

– Additively built structures are preferred due to scheduling

• Bonus points for structures that could be built in theater

– The lighter the structure, the better. Less weight means the UAV can carry more payload and fly longer

– Structure must fit within provided volume


Project #4Connecter Backshells

• Wire harnesses and connectors are a universal challenge throughout Lockheed Martin’s product lines. We currently procure backshells from connector manufacturers, and these current backshells limit our ability to separate signals coming out of the electronic assemblies and into the harness. Another issue with the current backshells are the internal sharp edges. Internal sharp edges can abrade and damage the wiring and cause signal loss from assembly to assembly.

Develop custom backshells that have the ability to efficiently separate signals coming out of the electronics assembly and into the harness as well as provide smooth internal surfaces removing any concern of wire abrasions.

– Develop and design:

• Single port

• Multi-port backshells– Multi-port design would be to provide the ability to separate the

signals coming out of the harness

– Backshells must be compatible to micro-D or D-sub connectors (MS24308 & Mil-DTL-83513-15)

– Backshell exit orifices shall have features to install band clamps once the harness has been installed

– Backshells must prevent wires from experiencing chaffing on the internal part of the backshell that would lead to wire damage and signal loss


Project #5USB Hub Mounting Bracket

• Due to a design requirements change a new USB mounting bracket needs to be designed

– From a 4 port hub To a 7 port hub

– From Horizontal mount To Vertical mount

– New cable retention for usbcables and power

– From single usb hub to stacked 3 high

– Environment 0 to +25C

– Must show that new bracket can survive vibration loading

Old Hub and Bracket

New Hub


Project #6Design for Additive

Lockheed Martin design teams have relied upon traditional methods of manufacturing (casting, machining, etc.) to solve our complex and complicated problems. As additive manufacturing continues to mature in quality and capability, our engineers must not only learn to use these techniques, but also learn how to design solutions to take advantage of additive manufacturing’s unique capabilities. The future lies not in additively manufacturing a screw, but rather designing and additively manufacturing a system that doesn’t need screws.

Research a part or component that reflects the products that Lockheed Martin provides to our customers. Review your selection with Lockheed Martin representatives before proceeding with design. Redesign that part to take advantage of the capabilities of additive manufacturing. Create a prototype of your new part out of plastic using a 3D printer. Demonstrate that your new part meets or exceeds the capability of the legacy design while providing one of the following:

– Reduced weight

– Reduced part count

– Faster / easier assembly

– Improved performance


Project ExampleCompleted by LM Engineers

Documents

Lockheed Martin - Pennsylvania State University Freshman Design Effort - LM... · –“Topology Optimization” ... • Lockheed Martin has many airborne platforms that were