Defense

April 3, 2013

State-of-the-art 3D printers cut costs, turnaround time

Engineering Tech Mikael Mead of Tobyhanna Army Depot, Penn., removes a small production run of finished lens covers from the printing tray of a polyjet 3-D printer. Three-dimensional printers produce parts out of plastic and other durable materials.

Engineers and technicians at Tobyhanna Army Depot, Penn., use a highly innovative, cutting-edge fabrication process to significantly cut costs and reduce turnaround time.

The depot’s additive manufacturing process uses two, three-dimensional 3-D printers to produce parts out of plastic and other durable materials. Unlike traditional design methods where a part is made from a block of material and the excess is discarded, additive manufacturing uses only material necessary for the part, saving money and minimizing waste.

Electronics Engineer Corey Sheakoski said the benefits and potential of this process are nearly unlimited.

“Tobyhanna has the ability to make any type of plastic part, as long as we have a 3D model for it and it fits within a certain set of dimensions,” he said. Sheakoski works in the Production Engineering Directorate’s, or PED’s, Mission Software Branch.

Recently, a shortage of parts was delaying delivery of Harris radios. The radios required the installation of small dust caps prior to shipping to the customer. Finding and getting the part from a vendor could have taken weeks; so instead, Mechanical Engineer Eugene Haikes designed a 3-D model of the part and the depot printed 600 dust caps in 16 hours.

Mikael Mead, engineering tech in PED’s Design and Development Branch, said the decision to make the part at the depot saved a substantial amount of money and precious time.

“If the depot wanted to produce the dust caps but didn’t have a rubber mold for them, we could have expected to pay anywhere from $5,000 to $15,000 for the mold,” said Mead. “Because Eugene was able to come up with the model, we were able to produce the caps for only a dollar apiece while trimming days, if not weeks, off of our anticipated delivery date.”

Haikes, who works in PED’s Manufacturing Engineering Branch, said the whole process provides added benefit to both the depot and the customer.

“Some parts can be made through 3-D printing that just cannot be produced by conventional methods,” he said. “Other advantages with this process are that machine time is not charged to the customer and it can run overnight and during the weekend.”

Tobyhanna has been using additive manufacturing since the arrival of the first 3-D printer in the fall of 2006. The process begins with a computerized 3-D model that is programmed into one of two high-tech printers. The machine then builds a part, layer by layer, based on the model’s design.

The depot’s first 3-D printer, a fused deposition modeling machine, or FDM, is capable of making parts out of ABS plastic within a 10 x 10 x 12 in. area. The second machine, a polyjet printer, was purchased in April 2012, and can make parts out of hundreds of composite materials within an 8 x 16 x 19 in. area.

The FDM machine produces parts accurate to one one-hundreth of an inch of the computerized model, while the polyjet printer is accurate to .002 inch. This capability also allows depot engineers to print parts to use as prototypes and test pieces.

Sheakoski added that the future of additive manufacturing and 3-D printing technology holds nothing but promise.

“When you look at some of the benefits of 3-D printing – the cost savings, reduction in turnaround times, reliability – it’s exciting to think where it can go from here,” he said. “Additive manufacturing is helping the depot cut costs during tough times while continually supporting the warfighter with high-quality products.”

Tobyhanna Army Depot is the Defense Department’s largest center for the repair, overhaul and fabrication of a wide variety of electronics systems and components, from tactical field radios to the ground terminals for the defense satellite communications network. Tobyhanna’s missions support all branches of the armed forces.

About 5,100 personnel are employed at Tobyhanna, which is located in the Pocono Mountains of northeastern Pennsylvania. Tobyhanna Army Depot is part of the U.S. Army Communications-Electronics Command. Headquartered at Aberdeen Proving Ground, Md., the command’s mission is to research, develop, acquire, field and sustain communications, command, control computer, intelligence, electronic warfare and sensors capabilities for the armed forces.

 




All of this week's top headlines to your email every Friday.


 
 

 

News Briefs August 18, 2014

New U.S. strikes in Iraq include land-based bombers The latest round of U.S. airstrikes in Iraq against the Islamic State extremist group includes the first reported use of land-based bombers in the military campaign. U.S. Central Command says a combination of bombers, fighter jets, attack planes and unmanned drones hit targets near Iraq’s largest dam...
 
 

Headlines August 18, 2014

News NATO would respond militarily to Crimea-style infiltration: general If Russia tries to infiltrate troops into a NATO country, even out of official military uniform as it did before it annexed Ukraine’s Crimea, NATO will respond militarily, the alliance’s top commander said in an interview published Aug. 17. http://www.reuters.com/article/2014/08/17/us-ukraine-crisis-breedlove-i...
 
 

U.S. Navy to test, evaluate Lockheed Martin industrial exoskeletons

Lockheed Martin has received a contract through the National Center for Manufacturing Sciences for the U.S. Navy to evaluate and test two FORTIS exoskeletons. This marks the first procurement of Lockheed Martin’s exoskeletons for industrial use. Terms of the contract were not disclosed. The FORTIS exoskeleton is an unpowered, lightweight exoskeleton that increases an operator’s...
 

 

Orbital completes third cargo delivery mission to ISS

Orbital Sciences Corporation, one of the world’s leading space technology companies, announced Aug. 18 the successful completion of its third cargo delivery mission to the International Space Station in the past 10 months, including the initial demonstration flight completed in October 2013 and the first two operational missions under the company’s $1.9 billion Commercial Resupply...
 
 

Brown extends tax credit to Northrop Grumman

California Gov. Jerry Brown has signed legislation that extends a $420 million state tax credit to aerospace giant Northrop Grumman after approving a similar deal for its competitor, Lockheed Martin. Brown’s office announced Aug. 15 that he signed SB718 by Sens. Richard Roth, D-Riverside, and Sen. Stephen Knight, R-Palmdale. It expands an aerospace tax credit...
 
 
Air Force photograph by SSgt. Sean Martin

Bomber crews showcase take-off talents

https://www.youtube.com/watch?v=F_8qr7ojpWg&feature=player_embedded Air Force photograph by SSgt. Sean Martin A B-52H Stratofortress starts its engines during a Minimum Interval Takeoff on Barksdale Air Force Base, La., Au...
 




0 Comments


Be the first to comment!


Leave a Reply

Your email address will not be published. Required fields are marked *

You may use these HTML tags and attributes: <a href="" title=""> <abbr title=""> <acronym title=""> <b> <blockquote cite=""> <cite> <code> <del datetime=""> <em> <i> <q cite=""> <strike> <strong>