Case Study of the Naval Surface Warfare Center Indian Head Energetic Materials Additive Manufacturing Initiative

Abstract

Additive Manufacturing (AM) is a manufacturing paradigm revered by the United States with inspired interest, as the Department of Defense strategizes to revitalize its industrial bases. The Office of Naval Research in collaboration with the Naval Surface Warfare Center Indian Head Division are conducting the Hercules Experimental Smokeless (HES) 5808 AM research and development. The HES 5808 is a critical component of the M91 Impulse Cartridge which is utilized in the AV-8, F-5, F-16 and T-38 Aircrew Escape System. The catalysts for the study are the high rate of defects and constraints of traditional manufacturing (TM). The study objective is to determine the efficacy of the AM methodologies, Direct Ink Write and Digital Light Processing, in relation to the manufacturing of propellant. Moreover, the long-term goal is to field the AM product upon the successful completion of Design Verification Testing and qualification.