Overview
Edison Welding Institute, Austal USA, Navus Automation,
NSWC-Carderock Division, NASSCO, HII Ingalls Shipbuilding
June 2019 – July 2021
INDUSTRY INVESTMENT: $1,315K | NSRP ASE INVESTMENT $1,315K
OBJECTIVE
This project’s overall goal is to develop a standardized robotic arc Directed Energy Deposition (DED) Additive Manufacturing (AM) gantry that can build a wide range of structures and components.
SUMMARY
This project will develop digital data workflow processes, establish workforce competencies, help break down process qualification barriers, demonstrate representative qualifications, and provide standardized equipment for robotic arc DED AM implementation.
KEY DELIVERABLES / BENEFITS
- 50% reduction in time and 25% reduction in cost of DED AM Process Implementation
- 33% ($1M) reduction in cost of Robotic Arc DED AM Gantry System vs. custom build
- 53% reduction in Arc DED AM qualification costs
PROJECT RESULTS
The project established a large, prototype DED-AM capability (reportedly the largest in North America) and demonstrated operation through a number of large, complex fabrications. This capability also demonstrated the workflow from CAD though robotic path planning, and facilitated training of shipyard members on its use. The project also supported development of NAVSEA Technical Publication of Process Requirements for DED-AM, which was released near the end of the project and was applied to construction of a Phase 2 test article. The project developed the design and specification for a future, shipyard-centric system deign for future implementation.
POINT OF CONTACT: Dennis Harwig | Edison Welding Institute | dharwig@ewi.org
Final Report approved for Public Release