Materials Testing and Cost Modeling for Composite Parts Through Additive Manufacturing

Abstract

Recent advances in additive manufacturing (3D printing) have introduced new parameters in reducing cost in manufacturing aircraft components. The additive process provides a possible means to reduce an aircraft's lifecycle cost (LCC), but the effects of changed process parameters of additive manufacturing machines on final material characteristics are not well known. This research explores these effects with the intent to motivate greater use and application in aviation. We conduct this study in two parts. First, focusing on fused filament fabrication (FFF) through Mark Forged, Inc's Mark One machine, this research creates PA6 dog-bone specimens for (1) a design of experiments (DOE) procedure and (2) a destructive test of a continuous fiber composite specimen from the Mark One machine. Second, this paper explores cost modeling issues using in the additive manufacturing industry with a specific focus on energy usage. Taken together, this research effort identifies critical factors in additive manufacturing towards revolutionizing the military supply chain.