The Future of Additive Manufacturing to Improve Naval Readiness
Distribution A: Approved for Public Release Anthony W. Dean, PhD
Jennifer G. Michaeli, PE, PhD Sebastian Bawab, PhD Michael Ploanco
Jonathan Ricci James Lambeth Carolyn Lambeth
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It is my strong belief that 3D printing and advanced
manufacturing are breakthrough technologies for our maintenance and
logistics functions in the future. - Vice Admiral Philip Cullom,
Deputy Chief of Naval Operations for Fleet Readiness and Logistics
Distribution A: Approved for Public Release
Slide 3
AM is the process of joining materials to make objects from 3D
model data, usually layer upon layer, as opposed to subtractive
manufacturing methodologies (ASTM International, 2012) Shapes can
be created not possible through traditional manufacturing
techniques allowing for the development of more efficient and
robust parts. By printing parts on site, inventory and shipping
costs can be reduced, and new or updated equipment can be digitally
distributed, allowing for a more rapid response to the warfighters
needs. What is Additive Manufacturing? Distribution A: Approved for
Public Release
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Material Extrusion Vat polymerization Material jetting Binder
jetting Powder bed fusion Sheet lamination Direct energy deposition
Most Common Types of Additive Manufacturing Distribution A:
Approved for Public Release
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Additive Manufacturing 3D Printing Rapid Prototyping Direct
Digital Manufacturing Where Additive Manufacturing is being used
Often referred to as: Distribution A: Approved for Public
Release
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Navy Specific Challenges Harsh operating environments Building
parts that can survive operating environments Printing quality
parts in operating environments Qualification and certification
challenges Safely and effectively utilize new materials and
processes as they become available Navy specifications and
standards 6 Maintaining compliance to existing standards Reviewing
and updating old standards Impact on lifecycle and acquisition for
Naval platforms and components Distribution A: Approved for Public
Release
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Product evolution Strategic imperative: Balance of agility,
innovation, and performance Value driver: Balance of efficiency,
risk, and time Key enabling AM capabilities: Customization to navy
requirements Increased product functionality Market
responsiveness/part availability Zero cost of increased complexity
Service model evolution Strategic imperative: Agility and
innovation Value driver: Efficiency and risk Key enabling AM
capabilities: Mass customization Manufacturing at point of use
Supply chain disintermediation Deckplate empowerment Stasis
Strategic imperative: Performance Value driver: Efficiency Key
enabling AM capabilities: Design and rapid prototyping Production
and custom tooling Supplementary or insurance capability Low rate
production/no changeover Supply chain evolution Strategic
imperative: Performance Value driver: Efficiency and time focus Key
enabling AM capabilities: Manufacturing closer to point of use
Responsiveness and flexibility Management of demand uncertainty
Reduction in required inventory Low impact on chain change High
impact on supply chain High impact on product Low impact on product
Adapted from 3D opportunity in the Department of Defense: Additive
manufacturing fires, Deloitte University Press Strategic Drivers:
Performance Innovation Agility` Value Creation: Efficiency Risk
Time Distribution A: Approved for Public Release
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How can AM help the warfighter? AM has the capability to bring
parts to the warfighter more quickly and cost effectively. By
printing parts on nearby military installations or eventually
shipboard, inventory can be reduced and shipping costs can be
nearly eliminated for many items. Within days or hours of
identifying a needed part, a model can be designed and uploaded to
a database for printing, allowing for a more rapid response to the
warfighters needs. AM can save time, decrease cost, and reduce
inventory for the U.S. Navy. Distribution A: Approved for Public
Release
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Address Navy S&T focus area of Total Ownership Cost
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Operational Availability Maintenance Repair Overhaul
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Operational Availability Maintenance Repair Overhaul
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Current Navy Initiatives Distribution A: Approved for Public
Release
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Print the Fleet began as a CNOs Rapid Innovation Cell (CRIC)
project dedicated to introducing AM to the Fleet Sponsor: Navy
Warfare Development Command (NWDC) Technical Lead: NSWC Dahlgren
(at CDSA Dam Neck) USS ESSEX Lead: Naval Postgraduate Dental School
History of Print the Fleet Distribution A: Approved for Public
Release
Slide 14
Provided an opportunity to educate the naval community and
build prototype non-critical parts for the Fleet Accomplishments:
Conducted a series of workshops, including the Navys first Maker
Faire Built non-critical parts for Fleet at shore and shipboard
Collected user feedback to catalog warfighter needs Worked with
NAVSUP to develop a AM data repository (in process) USS ESSEX
(LHD-2): uPrint installation, building of AM parts, and training of
sailors 14 Distribution A: Approved for Public Release
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Print the Fleet Scope and Deliverables NAVSUP partnered with
NWDC and CDSA Dam Neck to identify printable parts and create a
suitable infrastructure to host files and bring these parts from
the engineer to the warfighter. The scope of this project included
developing procedures for building parts, qualifying parts,
delivering parts, and training non- engineers in the use of 3D
printers. Feedback from all users will be recorded to continually
improve processes and procedures. Distribution A: Approved for
Public Release
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USS ESSEX (LHD 2) A uPrint (desktop 3D printer) was used to
test the feasibility of printing shipboard (dry docked). This
effort was led by NWDC, Naval Postgraduate Dental School, and the
USS ESSEX (LHD 2). Successes: Installation and use of a 3D printer
shipboard Training of USS Essex sailors on CAD software and using
the printer Distribution A: Approved for Public Release
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Example parts Oil Reservoir Cap Modeled by USS Essex Printed by
CDSA Dam Neck Bracket for Phone Jack Boxes Modeled and printed by
CDSA Dam Neck Ouija Board Pieces Modeled by USS Essex Printed by
CDSA Dam Neck Distribution A: Approved for Public Release
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Naval Engineering Education Center (NEEC) Project: Exploration
of Additive Manufacturing for Naval Applications Explores the
benefits and limitations of additive manufacturing in naval
applications, with the following specific objectives: Gain
knowledge on the Navys experience to date with 3D printing and
their near, mid and long term goals; Expose engineering students to
3D printing technology and capture the necessary time to train and
learning curve associated with gaining proficiency with the
technology as a benchmark for the Navys training needs; Conduct an
in-depth engineering and cost analysis of several shipboard systems
to determine which components may be replaced with 3D printed
parts; Design and build these parts to conduct rigorous
component-based testing and simulated-system testing to examine the
durability and reliability of the 3D printed parts in comparison to
the traditional parts; Provide recommendations to the Navy
regarding personnel training, shipboard system analysis and part
identification; testing and qualification, and other lessons
learned for additive manufacturing in Naval applications.
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Future Goals CDSA Dam Necks location in Virginia Beach and ODUs
Norfolk location enables engineers to provide direct support to the
Fleet in the Hampton Roads area. This positions this team to work
with over 20% of the Navy to develop a systematic approach to AM,
and, through these efforts, pave the way for our warfighters to
have 3D printing access. Similar hubs can be set up around the
world to provide support in additional locations. In the future, it
is expected that the warfighter will be able to print parts
worldwide, including aboard ship while underway Southeastern
Virginia is home to more than 20% of the entire United States Navy!
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