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The NCAMP Approach for Polymer AM
TASK 4:
TASK 2A: TASK 2B: Transition
TASK 1: Validate TASK 3:
Establish Steering Develop Establish statistical -Data and guidance
Qualification framework with to CMH-17
Committee Framework selected Polymer guidelines
AM material - Specifications to
SAE
4
America Makes - Project Overview
• Problem Statement: ULTEMä 9085 is a polyetherimide high performance thermoplastic material with application
acceptable strength-to-weight ratio and flame, smoke and toxicity (FST) rating. This material is often used in aerospace
where a high strength thermoplastic material is needed. As this material is one of the only high performance
thermoplastic materials available for Fused Deposition Modeling, it is important to establish a complete database of
material properties to further enable use in various commercial and government applications. Such a database is a
minimum requirement for deployment of an additively manufactured solution in a production environment.
• Objectives: 1) Ensure Process Control and create documentation; 2) Identity and publish appropriate test matrix for
process/material combination; 3) Fabricate test coupons; 4) Complete testing and publish results.
• Project Benefits: Completed database to allow membership to exploit for commercial applications; Framework for
future materials/processes will be completed and available to membership; Equivalency process will be defined for
membership to utilize outcomes in house.
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TASK 1: Steering Committee
Qualification Builds
3 Lots/2 Machines
at RP+M
* Outside of current project
scope, but NIAR project
deliverable will allow or
equivalency process for future
TEST
NOTES
• All qualification and equivalency coupons to
ANALYZE/PUBLISH
4 4 4 4 4 4
NO. SPECIMEN PER
TEST METHOD AND
. . . . . .
N o te s :
• 2 M a c h in e s a r e r e q u ir e d f o r q u a lif ic a t io n
24 SPECIMENS TOTAL h o w e v e r 3 o r m o re a re re c o m m e n d e d .
• E x t r a s p e c im e n s s h o u ld b e t e s t e d f o r e a c h
p ro p e rty a n d te m p e ra tu re a s “ s p a re s ” to
e n s u r e d e s ir e d q u a n t it y ( m in o f 3 s p e c im e n s ) .
NCAMP DOCUMENTATION STATUS
Raw STATUS
Resin
Spec. NCAMP
Filament Material Specification
Spec. • Final drafts of material and
process specs - complete
• Build and Pack files included
Build to reduce variation.
NCAMP
Material
Process Change Process Specification
Machine Control
Software
Shear Shear
Trial studies were conducted to define shear and com pression test m ethods with ISC input.
NCAMP Test Plans
Dispositioned Acceptable
12 12
TENSILE STRENGTH [ksi]
10 10
9 9
8 8
7 7
A B C A B C
Batch Batch
12 12
11 11
10 10
9 9
8 8
7 7
A B C A B C
Batch Batch
Variability – Machine, Batch
• CVs: 3 – 9%
• X and Y build directions
are poolable
• Few outliers
Sample Results – SSB, RTD condition
• Higher CVs
• X, Y and Z45 are
poolable
• Batch to batch
variability seen
IZOD Impact Resistance Data – Example of
Variation within Data
IZOD Impact
Fortus 900mc
Unnotched
-45/45
Im pact Resistance
ULTEM 9085
180
170
160
Im p a ct R e sista n ce (j/m )
150
140
130
120
110
100
90
80
70
60
50
40
30
20
XY XZ Z4 5 ZX
O rie n ta tio n
Task 3: Development of statistical guidelines
Allowab
les
Data
Specific
ation Equival
ency
limits
Task 4: Guidelines and Recommendations
RESULTS
– First publically available Material Allowables for the FDM Process and ULTEM 9085
– Repeatability proven for the first time – process is controlled
– Understood to be a Mature Process widely utilized by industry
– Control demonstrates machine repeatability through process specification
implementation
– Quantify material variability through process
– Quantify other design variables through process
C o m p le tio M ile s to n e /
A c tiv ity
n D a te D e liv e ra b le
1 .1 H o ld k ic k -o ff m e e tin g o n P B A M 8 /2 4 /2 0 1 6 M ile sto n e
ü
1 .2 In d u stry S te e rin g C o m m itte e 9 /3 0 /2 0 1 6 M ile sto n e
- E s ta b lis h g ro u p o f p a rticip a n ts
ü
- C re a te o n lin e p o rta l fo r d o cu m e n t sh a rin g a n d d a ta
re p o s ito ry
1 .3 P re lim in a ry d ra fts o f q u a lifica tio n fra m e w o rk 3 /3 1 /2 0 1 7 D e live ra b le
- M a te ria l a n d p ro c e s s sp e cifica tio n s
ü
- T e s t p la n
- C o n fo rm ity d o cu m e n ta tio n
1 .4 Q u a lifica tio n B u ild s 1 0 /1 5 /2 0 1 7 M ile sto n e
- S ite a u d it co m p le te
ü
- C o u p o n s b u ild s c o m p le te a n d d e live re d to N IA R
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Status – Based on FY2017 Deliverables
M ile s to n e /
A c tiv ity T a rg e t D a te
D e liv e ra b le Complete?
1 .1 L ite ra tu re R e v ie w 1 1 /3 0 /2 0 1 7 D e live ra b le
- C o n d u c t a lite ra tu re re vie w o f re le va n t P B A M
ü
R e s e a rc h .
- D o c u m e n t re s u lts o f th e re vie w in a te ch n ica l re p o rt.
1 .2 E q u iv a le n c y B u ild s 3 /1 /2 0 1 8 M ile sto n e
- S ite a u d it co m p le te
ü
- C o u p o n b u ild s co m p le te a n d d e live re d to N IA R
1 .3 Q u a lific a tio n T e s tin g 7 /1 /2 0 1 8 M ile sto n e
- P e rfo rm p h ys ic a l a n d m e ch a n ica l te stin g o n
ü
q u a lific a tio n b u ild s .
– G e n e ra te te st d a ta fo r q u a lific a tio n p ro g ra m .
1 .4 E q u iv a le n c y T e s tin g 8 /1 /2 0 1 8 M ile sto n e
- P e rfo rm p h ys ic a l a n d m e ch a n ica l te stin g o n
e q u iv a le n c y b u ild s .
– G e n e ra te te st d a ta fo r e q u iva le n cy p ro g ra m .
1 .5 D e v e lo p S ta tistic a l G u id e lin e s b a se d o n q u a lifica tio n 1 0 /1 /2 0 1 8 M ile sto n e
d a ta
1 .6 D e v e lo p E q u iva le n cy G u id e lin e s b a se d o n q u a lifica tio n 1 2 /3 1 /2 0 1 8 M ile sto n e
d a ta
1 .7 N C A M P R e p o rts o n Q u a lifica tio n D a ta 2 /2 8 /2 0 1 9 D e live ra b le
- M a te ria l te c h n ic a l re p o rt
- S ta tis tic a l a n a lys is te ch n ica l re p o rt
1 .8 C M H -1 7 5 /3 1 /2 0 1 9 D e live ra b le
- S u b m it co n te n t, d a ta , a n d p ro to co ls to C o m p o site
M a te ria ls H a n d b o o k 1 7 (C M H -1 7 )
1 .9 F in a l R e p o rt 8 /3 0 /2 0 1 9 D e live ra b le
- F in a l T e c h n ica l R e p o rt o n th e G u id e lin e s fo r P B A M
Q u a lific a tio n .
29
Looking forward
• Benefit to Aviation
– First AM qualification database with M&P specs
– Understanding of relevant considerations – how to qualify an AM
process, parameters, sources of variability
• Future needs
– Perform qualification on other AM materials, including
filled/reinforced AM or other processes
– Determine if framework can be pulled to metallic AM
– Machine Variability – machine type investigation
– Building Block – how do coupon properties correlate to part
properties
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