U.S. Air Force utilizes AM Software Senvol ML to develop methodology for multi-laser additive manufacturing program

U.S. Air Force is currently leading a collaboration between Air Force Research Laboratory (AFRL) and Air Force Life Cycle Management Center (AFLCMC). At the heart of this collaboration, is the development of a methodology for demonstrating airworthiness of multi-laser Additive Manufacturing.

AFRL is a global technical enterprise which leads the discovery, development, and integration of affordable warfighting technologies for the U.S. air, space, and cyberspace force.  AFLCMC provides holistic life cycle management and sustainment of every major Air Force weapon system from inception to retirement. UDRI specializes in scientific and engineering research, serving government, industry and nonprofit customers.

The methodology for multi-laser additive manufacturing program

To achieve this methodology, the team of this collaborative program is using an EOS M400-4 quad laser powder bed fusion machine as well as Senvol ML, software designed for additive manufacturing (AM).

Named “FlexSpecs,” the project consists in qualifying the EOS M400-4, by developing baseline mechanical properties and design allowables, and ultimately making demonstration builds of heat exchangers and hypersonics-relevant parts.

Speaking of their machine learning software, Senvol President Annie Wang explained that “Senvol ML is well-suited to assist with AM qualification, and this is a great example of that. In addition to helping to develop baseline mechanical properties and design allowables, the software will analyze data to evaluate laser-to-laser consistency, optimize bulk scan settings, identify preferred overlap patterns and parameters, and confirm uniformity over the entire build plate.”

Dr. Mark Benedict, Materials Scientist and Program Manager in the Propulsion, Structures & Industrial Technologies Branch, Manufacturing Technology Division, Materials and Manufacturing Directorate, AFRL, Air Force Materiel Command, commented, “The overall objective of this program is to successfully demonstrate full scale M400, multi-laser prints of heat exchangers as well as hypersonics-relevant parts. This is an area of need for the Air Force, and we look forward to the results.”

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