SBIR-STTR Award

During this Phase I effort Optomec will demonstrate that the Laser Engineered Net Shaping (LENS) process provides a viable means for both repair and fabrication of functional prototype components for the MPH needs. This work will serve to establish a benchmark part that can be used for calibration and set up of the LENS equipment, as well as other commercially available RP equipment. The goal of the benchmark part is to provide a standard test geometry that considers all of the critical aspects facing the RP industry and also a means to measure continued process improvements expected to occur in the Phase II effort. A unique aspect of the benchmark part to be defined during this project is that it will provide a means to means to measure fit, form and function for newly emerging RP methods such as the LENS process where functionality is now provided. The work proposed in this project will rely on input from an array of RP users such that a standardized benchmark can be developed that provides a standard that is readily accepted in the RP industry. The anticiapted benefits to be derived through this SBIR work include: demonstration that functionality can be achieved in rapid protoypes, demonstrate that the LENS process provides a viable means for repair and fabrication of metal perts, provide a standardized benchmark part for testing form, fit and function that serves as a standard for the RP industry

The primary objective of this Phase II Project is to provide a viable additive manufacturing solution for producing high performance metal parts using the LENSO technology. To meet this objective several of the current limitations of the existing LENSO process need to be overcome. In particular, a method must be identified and developed to overcome limited overhang capabilities available through the current LENSO process, material deposition rates should be improved, energy requirements for the process should be significantly reduced and powder utilization should be improved. Three areas of concentration are proposed for this project to provide the necessary improvements required to meet the objective of this project. These areas include software development, laser technology evaluation and implementation and improved nozzle designs. Although the preliminary work proposed for each of these areas of concentration will be performed somewhat independent of the others areas, it is important to note that there is a strong linkage between the developments in each of these areas. As such, the second half of the project will focus on integrating the best solutions from each area of concentration into a single system that will push the LENSä process technology forward to meet the needs of TACOM.

Keywords:
LASER ENGINEERED NET SHAPING LENS SFF ADDITIVE MANUFACTURING