Additive Manufacturing for Lightweight, Low Cost Seeker Gimbals

Award Information
Agency: Department of Defense
Branch: Army
Contract: W9113M-11-C-0023
Agency Tracking Number: A102-127-0515
Amount: $69,514.00
Phase: Phase I
Program: SBIR
Awards Year: 2010
Solicitation Year: 2010
Solicitation Topic Code: A10-127
Solicitation Number: 2010.2
Small Business Information
2380 Shasta Ave, Suite B, Simi Valley, CA, 93065
DUNS: 179616656
HUBZone Owned: N
Woman Owned: N
Socially and Economically Disadvantaged: N
Principal Investigator
 Dave Ciscel
 Vice President
 (805) 844-7819
 dave.ciscel@calraminc.com
Business Contact
 John Wooten
Title: President
Phone: (805) 844-7823
Email: john.wooten@calraminc.com
Research Institution
N/A
Abstract
Lightweight gimbal assemblies capable of meeting both thermal and structural requirements in military aviation environments can be accomplished through the use of titanium alloys. However, to achieve a production unit cost not to exceed $600-$1200 per gimbal assembly for a seeker gimbal assembly based on expectations for 20,000 to 30,000 gimbals is very challenging. CalRAM, Inc, a company established to do additive manufacturing, has been developing a near-net shape fabrication process capable of generating titanium components with physical and mechanical properties comparable to wrought titanium. The “tool-less” process called Electron Beam Melting (EBM) manufacturing produces parts directly from CAD files, uses an electron beam as the energy source and melts titanium powder in a heated powder bed. Since the process builds parts one-layer at a time, several details can be integrated into each layer reducing part count. CalRAM’s vision to accomplish the high-volume and low-cost targets will be to create a dedicated manufacturing cell based on EBM fabrication coupled with CNC machining, inspection, cleaning and packaging. The goal of Phase I is to develop a recommendation for the leading approach to produce gimbal assemblies for Phase II.

* Information listed above is at the time of submission. *

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