Defense

August 14, 2013

Army Research Lab, Purdue explore 3-D printing to fix deployed equipment, cut maintenance costs

T'Jae Gibson
Aberdeen Proving Ground, Md.

New technology being developed by research engineers at the U.S. Army Research Laboratory and Purdue University will soon help just about any soldier deployed in far-off locations to immediately spot and fix damaged aircraft and ground vehicle parts.

Researchers found that combining the general purpose, finite-element analysis software ABAQUS with Python, an open-source code used to optimize logical structures such as topologically interlocked structures, improves energy absorption and dissipation, productivity and lower maintenance costs.

The combination of ABAQUS and Python provides an automated process for auto-generation of the geometries, models, materials assignments and code execution, said Ed Habtour, a research engineer with U.S. Army Research Laboratory’s, or ARL’s, Vehicle Technology Directorate at Aberdeen Proving Ground, Md.

He said the code is developed to assist designers with tools to model the new generation of 3-D additive manufactured and TISs structures.

“The benefit for the soldier is an after-effect,” Habtour said. “The TIS would provide an excellent energy absorption and dissipation mechanism for future vehicles using additive manufacturing. Subsequently, the Soldier can print these structures in the field using additive manufacturing by simply downloading the model generated by the designer/vendor.”

The research team developed logical structures from the mini-composition of tetrahedron-shaped cells in existing materials, an approach ARL research engineers say is a vast departure from the military’s tendency to build new materials to meet existing problems.

“Traditionally, every time the U.S. Army encounters a problem in the field the default has been to develop new and exotic materials. Using logical structures can be effective in solving some critical and challenging problems, like the costly and time-consuming certification process that all new materials must face,” Habtour said.

This logical structure is based on principles of segmentation and assembly, where the structure is segmented into independent unit elements then reconfigured/assembled logically and interlocked in an optimal orientation to enhance the overall properties of the structure, Habtour explained.

The researchers are focusing on topologically interlocked structures using VTD’s 3-D additive manufacturing approach to build 2-D and 3-D structures based on cells in the shape of Platonic solids.

Habtour said new structures created from this process are designed to be adaptive and configurable to the harsh conditions like random and harmonic vibrations, thermal loads, repetitive shocks due to road bumps, crash and acoustic attenuation. An added bonus he said is that these structures are configured to prevent crack propagation.

“Sometime in the near future, Soldiers would be able to fabricate and repair these segmented structures very easily in the front lines or Forward Operating Bases, so instead of moving damaged ground or air vehicles to a main base camp for repair, an in-field repair approach would essentially mean vehicles would be fixed and accessible to war fighters much faster at lower costs,” said Habtour. “We want to change the conventional thinking by taking advantage of exciting materials and manipulating the structure based on the principle of segmentation and assembly.”

ARL is working closely with project managers at The U. S. Army Aviation and Missile Research Development and Engineering Center. Discussions are already underway to transition this work to AMRDEC and Tank Automotive Research, Development and Engineering Center developmental programs.




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


 
 

 

Headlines September 3, 2015

News Carter To China: US ‘Will Fly, Sail, Operate Wherever Law Allows’ Defense Secretary Ash Carter, in a speech billed as all about a new personnel approach for the Pentagon, laid out a clear line in the sand of the temporary islands the Chinese have been building. http://breakingdefense.com/2015/09/carter-to-china-us-will-fly-sail-operate-wherever-law-allows/ LRS-B details emerge: Major t...
 
 

News Briefs September 3, 2015

Soldier injured after parachute failed to deploy A soldier was injured during a U.S. Army Special Operations parachute training exercise in western Montana. Army officials at Fort Bragg, N.C., say 16 soldiers were conducting a free-fall parachute jump from two Blackhawk helicopters near Hamilton Aug. 31 when one soldier had an equipment malfunction and was...
 
 

Boeing, Jet2.com finalize order for 27 Next Generation 737-800s

Boeing and UK Leisure Airline Jet2.com have finalized an order for 27 Next Generation 737-800s, valued at approximately $2.6 billion at current list prices. Jet2.com currently operates an all-Boeing fleet of nearly 60 aircraft; however, this is the organization’s first direct Boeing order.† The aircraft will be used to take the company’s package holiday and...
 

 
boeing-emirates

Boeing, Emirates celebrate airline’s 150th 777 delivery

Boeing and Emirates Airline Sept. 3 celebrated the simultaneous delivery of three 777s — two 777-300ERs and one 777 Freighter — marking the entry of the 150th 777 into Emirates’ fleet. The delivery marks the first tim...
 
 

U.S. Air Force selects Chromalloy for F108 gas turbine engine module repairs

Chromalloy announced Sept. 2 that it has been selected by the U.S. Air Force to provide repairs on low pressure turbine modules for the F108 aircraft engine fleet, in a contract valued at up to $74 million. The one-year agreement was contracted by the Tinker Air Force Base in Oklahoma and includes four one-year options...
 
 
raytheon-colorado

Raytheon expanding in Colorado Springs

Raytheon will speed up growth of its Colorado Springs presence after signing a $700 million multi-year indefinite-delivery/indefinite-quantity contract to support operations at NORAD’s Cheyenne Mountain Complex. Under the...
 




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=""> <s> <strike> <strong>