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Lockheed Martin
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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
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Lockheed Martin
100+ Years of Accelerating Tomorrow
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Business Areas
Space
Systems
Mission Systems &
Training
Missiles & Fire
Control
Aeronautics
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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
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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
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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
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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
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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.
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2016 Project Overview
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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.
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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.
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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
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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
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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
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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
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Project ExampleCompleted by LM Engineers