Philip Greiner, Mechanical Engineer, Naval Surface Warfare Center – Philadelphia Division
Scott A. Storms, Mechanical Engineer, Naval Surface Warfare Center – Philadelphia Division
The Naval Surface Warfare Center Philadelphia Division (NSWCPD) has been applying Additive Manufacturing (AM) to US Navy applications with the Objet350 Connex3 printer; the multi-material capabilities have enabled applications in areas not previously explored with AM. Test fixtures for Rogowski Coil sensors were 3D modeled and printed to keep the sensor concentric with the cable it was measuring. The rigid material served as the preferred option for the edges of the mount, while the flexible material was used at the contact points with the cable to prevent any damage to the high-voltage cables and ensure a secure fit. AM has also been used to print seal whiskers and biofouling for sensor research and hydrodynamic testing, respectively. The prints will be tested for replication of the organic material. Testing the prints instead of the original material made tests more repeatable and consistent. Finally, the Objet printer has been used to print injection molds. This has been tested with a handle that is problematic and continues to break. The handle has been modified to enhance strength, 3D printed to ensure proper fitment and function, and the mold was printed to make high volumes of the handle.