Direct Part Manufacturing (DPM) for Nonstructural Components

Award Information
Agency: Department of Defense
Branch: Air Force
Contract: FA8650-09-C-5317
Agency Tracking Number: F081-043-0015
Amount: $1,398,160.00
Phase: Phase II
Program: SBIR
Awards Year: 2009
Solicitation Year: 2008
Solicitation Topic Code: AF081C-043
Solicitation Number: 2008.1
Small Business Information
Royal Plastic Mfg., Inc.
1046 E. 9th Street, Minden, NE, 68959
DUNS: 063119221
HUBZone Owned: N
Woman Owned: N
Socially and Economically Disadvantaged: N
Principal Investigator
 Tim O''Dey
 Engineering Manager
 (308) 832-2760
Business Contact
 Jarrod Ridge
Title: Business Development
Phone: (308) 832-2760
Research Institution
As rapid prototyping methodology evolves into rapid manufacturing reality, successful application hinges increasingly upon the available material selection and corresponding optimized process parameters. Research is being completed specific to the laser sintering process to develop next generation high temperature materials and hardware that will satisfy or exceed the increasing demands of industry. Obstacles to the integration of high temperature polymers and the laser sintering process include hardware limitations and material/process interactions and development.  Current laser sintering machines typically require heavy modification to process at elevated temperatures.  Additionally, the requisite materials are sometimes hindered by process compatibility   The presentation will focus upon hardware advancements made with EOS beta version P700 high temperature equipment (up to 350° C) and the parallel material development effort that has been underway for over two years.  Specific attention will be given to pitfalls encountered during development and on optimization results.  Both dimensional and mechanical property results will be shown to support the case. BENEFITS: Part candidates have been identified for the F-35 Joint Strike Fighter program.  Successful qualification of a high temperature thermoplastic may yield as many as 1200 piece parts per airframe in various clips, brackets and air ducts.  Cost savings at the non recurring level and recurring level are significant with the current cost model projections.

* information listed above is at the time of submission.

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