The Navy suffers from long lead times to obtain replacements for broken and worn parts. Additive manufacturing (AM) offers the potential to reduce supply-chain issues through shipboard manufacturing of replacement parts on an as-needed basis. Because AM machines are not inherently designed to MIL standards, modular control systems are needed to mitigate environmental effects on the machines as well as the effects that the machines have on their environment. AM machine operators need a modular, universal control system that mitigates the harmful effects of vibration and ship motion, provides temperature and humidity control, and filters out harmful ultrafine particles (UFPs) and volatile organic compounds (VOCs) emissions. ARiA will develop the standalone Trimodal Universal Portable Control (TUPAC) system that will provide: broadband active and passive vibration mitigation, a novel evacuation system that removes UFPs and VOCs at the source, and temperature and humidity control for the filament before and during the printing process. The TUPAC system design will ensure minimal noise and electromagnetic interference (EMI) impact on the operators and surrounding equipment, respectively. Each subsystem will be adaptable to fused deposition modeling (FDM) style printers of all makes and models, and are dual-use technologies that can be used independently.
Benefit: ARiAs TUPAC system provides a modular system composed of many COTS components that are adaptable to fused deposition modeling (FDM) style printers of all makes and models so that the utility of AM machines are realized in all types of operating environments. Each subsystem within TUPAC operates independently and are, therefore, selectable and adaptable to each AM machines needs and can be used for other applications when the AM machine is not operational. A novel, minimally invasive, evacuation system removes harmful aerosol emissions at the source with greater efficiency at a fraction of the cost, weight, and power consumption than currently available market solutions. The TUPAC system provides broadband vibration isolation from 0.1 - 1000 Hz with more than 90% efficiency above 3.5 Hz and added passive isolation beyond 1 kHz. The TUPAC system provides temperature and humidity control ensuring that moisture is not absorbed into the filament prior to printing, thereby improving the geometric accuracy, mechanical properties, and surface finish of the final part. As the TUPAC system is developed, each of these subsystems will be designed and/or modified as needed in order to meet MIL certification standards. The TUPAC system will minimize health hazards to sailors, improve build quality, reduce rework, and reduce the time required to optimize printer settings for harsh environments; thereby, increasing the readiness, sustainment, and enhanced warfighting capabilities of the Navy.
Keywords: Modular Controls, Modular Controls, Active vibration isolation, adaptive controls, Environmental Controls, Aerosol Filtration System, additive manufacturing
