Analysis of MELD Additive Friction Stir Deposition Applications to Improve the Production of Low-Cost Attritable UAVs

Hepburn and Sons LLC, integrator and leader in technology transition, has teamed with MELD Manufacturing Inc., with support from the University of Dayton Research Institute (UDRI) and Kratos Defense & Security Solutions, Inc., to propose to conduct a thorough Analysis of Alternatives (AoA) for the application of MELD, a new and advanced method of additive friction stir deposition. Our team will compare MELD to the current state of Additive Manufacturing (AM) techniques that will improve and lower the construction costs of Low-Cost Attritable Aircraft Technology (LCAAT) and other unmanned aerial vehicles (UAVs). Having met with UDRI and Kratos to evaluating specific applications, we are considering a key component for analysis and demonstration of MELD in Phase I: the mid wing bulkhead of the Kratos XQ-58A Valkyrie. We will construct a prototype using MELD as part of Phase II, along with mechanical testing. The mid wing bulkhead is the highest loaded bulkhead in the Valkyrie vehicle. Our Phase I study will assess cost reduction, risk, TRL, MRL, and feasibility of applying the MELD technology for the mid wing bulkhead production to increase efficiency, strength margin, while reducing cost. This new capability will enable the U.S. Air Force to 3D print aerospace-grade airframe assemblies in a timely and cost-effective manner.