Developing the ACCELERATE framework for compatibility: E-PBF and L-PBF, various platforms, diverse brands.
Problem
Metal additive manufacturing (AM) has revolutionized industrial sectors, notably aerospace applications, by enabling intricate and efficient production of customized metal components. However, the validation and qualification process, especially operational qualification (OQ), presents a significant challenge as it involves rigorous verification and validation of processes and procedures such as machine calibration, statistical validation via mechanical testing, process failure mode and effect analysis (PFMEA), powder feedstock control, facility and machine peripheral controls, software configuration and version control, operator training, and more. This complexity makes it both costly and time-intensive.
Objective
The team aims to establish a reliable OQ framework for electron beam power bed fusion (E-PBF) and L-PBF, in line with the Air Force’s specifications, DoD Instruction 5000.93. To achieve this, the action plan involves collecting and analyzing relevant OQ data, refining the OQ testing process, and setting up a data-driven framework for post-build sample analysis. This comprehensive approach should provide guidance and valuable insights to the Air Force, Air Force Research Laboratory (AFRL), and Department of Defense (DoD), to help them make informed decisions and reduce time and money spent on the OQ.
Technical Approach
Building on insights derived from data analysis and stakeholder engagement, the project team will construct a comprehensive OQ framework that addresses both E-PBF and L-PBF technologies. This framework is designed for compatibility and seamless integration across diverse platforms and brands. Beyond mere guidelines, it will encompass precise procedures and best practices for the OQ of platforms responsible for producing end components, particularly for Air Force hardware applications. Through the presentation of a well-structured methodology, the proposed OQ framework will facilitate a comprehensive assessment and validation of the reliability, safety, and performance of E-PBF and L-PBF systems. It will serve as an asset for industry adopters, regulatory agencies, and other relevant stakeholders. Ultimately, its accessibility will accelerate the adoption and widespread integration of E-PBF and L-PBF systems thereby enhancing the mission readiness for the Air Force and boosting the U.S. supply chain robustness.
Project Participants
Project Principal
Other Project Participants
- Addiguru
- Beehive Industries
- EOS
- University of Michigan
Public Participants
- U.S. Department of Defense