Portfolio Status: Projects In Progress

5554.003 3D Ceramic Research & Extensive Application of Tools for Engineered Molds (3D CREATE)

July 17, 2024

Renaissance Services, Inc. (RSI) has identified five technical focus areas to address the success factors for ceramic AM. The first focus area is a better surface finish for AM ceramic tooling,...

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5554.002 Additive Manufactured Ceramic Shell Technology for Investment Casting

July 12, 2024

The project aims to develop an AM shell building process for producing investment cast parts that conform to military quality standards and achieve Technology Readiness Level (TRL) and...

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5561 Large-Scale Additive Manufacturing with Advanced Thermoset and Thermoplastic Materials

June 28, 2024

This project seeks to advance the state-of-the-art for large-scale thermoset additive manufacturing. In addition to machine development, materials characterization and process development will be...

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5553 Hybrid Manufacturing for Rapid Tooling and Repair – Phase 2

June 28, 2024

Building off of the work in Phase 1 (Project 5524), the team will develop the hardware and software tools required to repair tooling components using a hybrid manufacturing process. These tools...

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5562.001 Accelerating Additive in DoD Applications of High-Performance Recycled Polymers

June 28, 2024

This project aims to create a cost-effective, sustainable supply chain for rPET suitable for fused filament fabrication (FFF) 3D printing while ensuring it meets the functional performance...

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5566.002 Proliferation of Nickel Superalloy Material Datasets for Powder Bed Fusion Additive Manufacturing

June 10, 2024

This material qualification program establishes a statistically valid dataset for high-strength nickel, ABD®900AM allowables for components manufactured using laser powder bed fusion (LPBF)...

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5568.001 Maturing AM Technology for C-103 in Hypersonics and Space (MATCHAS)

June 10, 2024

The Maturing AM Technology for Nb-C103 in Hypersonics and Space (MATCHAS) program is addressing critical feedstock supply chains for Nb-C103. This program specifically addresses the cost of...

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5567.005 Build Area Qualification Through Statistical Modeling of Melt Pool and Defect Distributions

May 22, 2024

The objective of the project is to characterize process variability through metallography and X-ray computed tomography (XCT), statistically modeled melt pool dimensions and defect size, and...

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5567.003 Sensor-Based Approaches to LPBF Machine Pre-Qualification

May 22, 2024

This project seeks to utilize sensor-based data sets, correlated to gas flow characterization, to pre-qualify machines and manufacturers to enable quality parts across the additive manufacturing...

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5566.003 Proliferation of AM Material Datasets, Topic 1 – Aluminum Alloy Material Datasets, Generation of Design Allowable Datasets for A7050-RAM Based on MMPDS C/D-basis Guidelines

April 29, 2024

This testing program establishes statistically valid high-strength aluminum, A7050-RAM2, material properties using laser powder bed fusion (LPBF) with guidance from the Metallic Materials...

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5567.004 AM Process Pre-Qualification

April 24, 2024

The objective is to demonstrate a reusable method to reduce the cost of LPBF process qualification by up to 40% for the pre-qualification of the LPBF process and develop a QMP to produce a set of...

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5001.004.001.004 Inspection Using In-Situ Height Mapping

March 23, 2024

Develop a framework to leverage in-situ process monitoring data to virtually reconstruct the part and inspect complex internal features for fidelity and dimensionality. Acquired data can be...

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