Advanced Infusion Techniques with 3-D Printed Tooling

Nuttall, David; Elliott, Amy; Post, Brian K.; Love, Lonnie J.

doi:10.2172/1257908

Title: Advanced Infusion Techniques with 3-D Printed Tooling

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Abstract

The manufacturing of tooling for large, contoured surfaces for fiber-layup applications requires significant effort to understand the geometry and then to subtractively manufacture the tool. Traditional methods for the auto industry use clay that is hand sculpted. In the marine pleasure craft industry, the exterior of the model is formed from a foam lay-up that is either hand cut or machined to create smooth lines. Engineers and researchers at Oak Ridge National Laboratory s Manufacturing Demonstration Facility (ORNL MDF) collaborated with Magnum Venus Products (MVP) in the development of a process for reproducing legacy whitewater adventure craft via digital scanning and large scale 3-D printed layup molds. The process entailed 3D scanning a legacy canoe form, converting that form to a CAD model, additively manufacturing (3-D Print) the mold tool, and subtractively finishing the mold s transfer surfaces. Future work will include applying a gelcoat to the mold transfer surface and infusing using vacuum assisted resin transfer molding, or VARTM principles, to create a watertight vessel. The outlined steps were performed on a specific canoe geometry found by MVP s principal participant. The intent of utilizing this geometry is to develop an energy efficient and marketable process for replicating complexmore »« less

Authors:

Nuttall, David ^[1]; Elliott, Amy ^[1]; Post, Brian K. ^[1]; Love, Lonnie J. ^[1]

Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)

Publication Date:: Tue May 10 00:00:00 EDT 2016

Research Org.:: Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Manufacturing Demonstration Facility (MDF)

Sponsoring Org.:: USDOE Office of Energy Efficiency and Renewable Energy (EERE)

OSTI Identifier:: 1257908

Report Number(s):: ORNL/TM-2016/192
ED2802000; CEED492; CRADA/NFE-15-05575

DOE Contract Number:: AC05-00OR22725

Resource Type:: Technical Report

Country of Publication:: United States

Language:: English

Subject:: 42 ENGINEERING

Citation Formats


                    Nuttall, David, Elliott, Amy, Post, Brian K., and Love, Lonnie J. Advanced Infusion Techniques with 3-D Printed Tooling.  United States: N. p., 2016. 
        Web.  doi:10.2172/1257908.

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                    Nuttall, David, Elliott, Amy, Post, Brian K., & Love, Lonnie J. Advanced Infusion Techniques with 3-D Printed Tooling.  United States.  https://doi.org/10.2172/1257908

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                    Nuttall, David, Elliott, Amy, Post, Brian K., and Love, Lonnie J. 2016.  
        "Advanced Infusion Techniques with 3-D Printed Tooling".  United States.  https://doi.org/10.2172/1257908.  https://www.osti.gov/servlets/purl/1257908.

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@article{osti_1257908,

  title        = {Advanced Infusion Techniques with 3-D Printed Tooling},

  author       = {Nuttall, David and Elliott, Amy and Post, Brian K. and Love, Lonnie J.},

  abstractNote = {The manufacturing of tooling for large, contoured surfaces for fiber-layup applications requires significant effort to understand the geometry and then to subtractively manufacture the tool. Traditional methods for the auto industry use clay that is hand sculpted. In the marine pleasure craft industry, the exterior of the model is formed from a foam lay-up that is either hand cut or machined to create smooth lines. Engineers and researchers at Oak Ridge National Laboratory s Manufacturing Demonstration Facility (ORNL MDF) collaborated with Magnum Venus Products (MVP) in the development of a process for reproducing legacy whitewater adventure craft via digital scanning and large scale 3-D printed layup molds. The process entailed 3D scanning a legacy canoe form, converting that form to a CAD model, additively manufacturing (3-D Print) the mold tool, and subtractively finishing the mold s transfer surfaces. Future work will include applying a gelcoat to the mold transfer surface and infusing using vacuum assisted resin transfer molding, or VARTM principles, to create a watertight vessel. The outlined steps were performed on a specific canoe geometry found by MVP s principal participant. The intent of utilizing this geometry is to develop an energy efficient and marketable process for replicating complex shapes, specifically focusing on this particular watercraft, and provide a finished product for demonstration to the composites industry. The culminating part produced through this agreement has been slated for public presentation and potential demonstration at the 2016 CAMX (Composites and Advanced Materials eXpo) exposition in Anaheim, CA. Phase I of this collaborative research and development agreement (MDF-15-68) was conducted under CRADA NFE-15-05575 and was initiated on May 7, 2015, with an introduction to the MVP product line, and concluded in March of 2016 with the printing of and processing of a canoe mold. The project partner Magnum Venous Products (MVP) is a small business. Phase II as discussed herein is under consideration by MVP as of this writing. Overall, it is anticipated that developing this process for manufacturing tooling for complex contoured surfaces has applicability to naval and other watercraft as well as bathrooms and large trucks.},

  doi          = {10.2172/1257908},

  url          = {https://www.osti.gov/biblio/1257908},
  journal      = {},
number       = ,

  volume       = ,

  place        = {United States},

  year         = {Tue May 10 00:00:00 EDT 2016},

  month        = {Tue May 10 00:00:00 EDT 2016}

}

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