Connecticut Center for Advanced Technology (CCAT), a not-for-profit, will agnostically demonstrate multiple examples of validated toolchains applied to DED. Breakthrough toolchains assembled of components from many providers and validated by CCAT have made it possible to predict and create DED parts of improved commercial value and removed many of the barriers to entry for this class of AM. Project outcomes and workforce inclusion are improved; lead times and cost are reduced by approaching DED from the perspective of toolchains, accessibility, and inclusion.
We will show a historic DED entry cost starting at a million dollars or more and requiring multiple subject matter experts with specialized experience and/or graduate education or above. We will contrast this to reliable good outcomes in DED by a small team of associates and bachelor’s degree educated staff and an equipment/software tool investment of under $200k. Incremental upgrades can increase capability well past the current state of the art. Presenters will explain the relevance of selected artifact builds to actual parts and why software and/or hardware tools are needed in the process.
Several examples of builds will be demonstrated as case studies using toolchains with recent elements from multiple vendors. Toolchains begin at appraising projects for DED suitability, through design phase using simple CAD tools and advanced generative design or reverse engineering, may be simulated and adapted for near-net-shape, sliced, G-code is generated, robot translation is utilized, robot motion is simulated for collisions and process improvement, process settings are applied, another round of distortion analysis may or may not be performed, and the physical part is produced. Post processing including hybrid manufacturing will be touched upon. Non-contact inspection is used to compare the resultant build to a solid model demonstrating 3D deviation mapping and MBD automated inspection reporting.
Learning Objectives:
- Understand DED as a whole process and how it
- Confidently send work out for DED fabrication or select tools and equipment to enter the workforce or add software and equipment for adoption of the technology in-house
- Upgrade your existing DED processes or use components of example toolchains in your own process, even if it is not DED.
