May 30, 2018
America Makes selects two UTRC additive manufacturing projects for awards

UTC's Research Center has been selected for two awards in Phase 3 of America Makes' "Maturation of Advanced Manufacturing for Low-Cost Sustainment (MAMLS)" program

YOUNGSTOWN, Ohio - United Technologies Research Center (UTRC) has been selected for award by the U.S. Department of Defense's "America Makes" initiative for its Maturation of Advanced Manufacturing for Low-Cost Sustainment (MAMLS) program. The program is funded by the Air Force Research Laboratory (AFRL), Materials and Manufacturing Directorate, Manufacturing and Industrial Base Technology Division.

"We are excited to be announcing the awardees of our latest Project Call at the kick off of exhibits at the additive manufacturing (AM) industry's largest event, RAPID + TCT 2018," said America Makes Executive Director Rob Gorham. "These seven awarded applied research and development projects will have a tremendous impact on ensuring the strategic readiness of the U.S. Air Force. The anticipated project outcomes will empower the sustainment community to adopt advanced additive manufacturing technologies, improving rapid part replacement/maintenance for legacy aircraft, enabling on-demand replacement of critically damaged or obsolete components, and reducing the cost and lead time to fabricate replacement components. We congratulate the winning project teams and look forward to getting these projects underway."

The first project for which UTRC was selected was categorized as "Emerging Process Technology for Low Criticality Part Families." Led by UTRC, in collaboration with Carbon, and UTC Aerospace Systems, this project will investigate the capability of Carbon’s emerging Continuous Liquid Interface Production (CLIP) process and supporting fabrication technologies to advance the Manufacturing Readiness Level (MRL) related to the AM of low-criticality polymer components for aerospace applications with a specific emphasis on masks, enclosures, and ducting.

In addition to exploring the CLIP process for its capabilities to manufacture low criticality components, this project also aims to demonstrate a complete end-to-end digital additive workflow, which encompasses part digitalization, design optimization, print process optimization, materials characterization, and component performance validation. The second project was selected under the category of "Understanding Manufacturing Realities of AM." Led by Penn State ARL, UTRC is collaborating on "Understanding Stochastic Powder Bed Fusion AM Flaw Formation and Impact on Fatigue." Other team members include 3D Systems, Oerlikon, and Moog, Inc.

This project will strive to minimize the seemingly random and sporadic stochastic flaws that occur in components produced by laser powder bed fusion (LPBF), even when manufactured under optimized processing conditions. The goal of this project is to quantify the effect of defects by building a high quantity of fatigue samples to generate statistically significant, pedigreed Ti-6Al-4V fatigue data from numerous stochastic flaws, enabling the project team to define the link between the process, the flaw characteristics, and fatigue performance.

For more information on the program, please see the America Makes press release.

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