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Title: Feasibility of using Big Area Additive Manufacturing to Directly Manufacture Boat Molds

Abstract

The goal of this project was to explore the feasibility of using Big Area Additive Manufacturing (BAAM) to directly manufacture a boat mold without the need for coatings. All prior tooling projects with BAAM required the use to thick coatings to overcome the surface finish limitations of the BAAM process. While the BAAM process significantly lowers the cost of building the mold, the high cost element rapidly became the coatings (cost of the material, labor on coating, and finishing). As an example, the time and cost to manufacture the molds for the Wind Turbine project with TPI Composites Inc. and the molds for the submarine project with Carderock Naval Warfare Systems was a fraction of the time and cost of the coatings. For this project, a catamaran boat hull mold was designed, manufactured, and assembled with an additional 0.15” thickness of material on all mold surfaces. After printing, the mold was immediately machined and assembled. Alliance MG, LLC (AMG), the industry partner of this project, experimented with mold release agents on the carbon-fiber reinforced acrylonitrile butadiene styrene (CF ABS) to verify that the material can be directly used as a mold (rather than needing a coating). In addition, for largemore » molds (such as the wind turbine mold with TPI Composites Inc.), the mold only provided the target surface. A steel subframe had to be manufactured to provide structural integrity. If successful, this will significantly reduce the time and cost necessary for manufacturing large resin infusion molds using the BAAM process.« less

Authors:
 [1];  [1];  [1];  [1];  [1]
  1. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Publication Date:
Research Org.:
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Sponsoring Org.:
USDOE Office of Energy Efficiency and Renewable Energy (EERE), Advanced Manufacturing Office (EE-5A)
Contributing Org.:
AllianceMG, LLC, Bellevue, WA (United States)
OSTI Identifier:
1427645
Report Number(s):
ORNL/TM-2017/709
DOE Contract Number:  
AC05-00OR22725
Resource Type:
Technical Report
Country of Publication:
United States
Language:
English
Subject:
42 ENGINEERING

Citation Formats

Post, Brian K., Chesser, Phillip C., Lind, Randall F., Sallas, Matthew R., and Love, Lonnie J. Feasibility of using Big Area Additive Manufacturing to Directly Manufacture Boat Molds. United States: N. p., 2018. Web. doi:10.2172/1427645.
Post, Brian K., Chesser, Phillip C., Lind, Randall F., Sallas, Matthew R., & Love, Lonnie J. Feasibility of using Big Area Additive Manufacturing to Directly Manufacture Boat Molds. United States. doi:10.2172/1427645.
Post, Brian K., Chesser, Phillip C., Lind, Randall F., Sallas, Matthew R., and Love, Lonnie J. Mon . "Feasibility of using Big Area Additive Manufacturing to Directly Manufacture Boat Molds". United States. doi:10.2172/1427645. https://www.osti.gov/servlets/purl/1427645.
@article{osti_1427645,
title = {Feasibility of using Big Area Additive Manufacturing to Directly Manufacture Boat Molds},
author = {Post, Brian K. and Chesser, Phillip C. and Lind, Randall F. and Sallas, Matthew R. and Love, Lonnie J.},
abstractNote = {The goal of this project was to explore the feasibility of using Big Area Additive Manufacturing (BAAM) to directly manufacture a boat mold without the need for coatings. All prior tooling projects with BAAM required the use to thick coatings to overcome the surface finish limitations of the BAAM process. While the BAAM process significantly lowers the cost of building the mold, the high cost element rapidly became the coatings (cost of the material, labor on coating, and finishing). As an example, the time and cost to manufacture the molds for the Wind Turbine project with TPI Composites Inc. and the molds for the submarine project with Carderock Naval Warfare Systems was a fraction of the time and cost of the coatings. For this project, a catamaran boat hull mold was designed, manufactured, and assembled with an additional 0.15” thickness of material on all mold surfaces. After printing, the mold was immediately machined and assembled. Alliance MG, LLC (AMG), the industry partner of this project, experimented with mold release agents on the carbon-fiber reinforced acrylonitrile butadiene styrene (CF ABS) to verify that the material can be directly used as a mold (rather than needing a coating). In addition, for large molds (such as the wind turbine mold with TPI Composites Inc.), the mold only provided the target surface. A steel subframe had to be manufactured to provide structural integrity. If successful, this will significantly reduce the time and cost necessary for manufacturing large resin infusion molds using the BAAM process.},
doi = {10.2172/1427645},
journal = {},
number = ,
volume = ,
place = {United States},
year = {2018},
month = {1}
}

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