Volume-aware design of composite molds

© 2019 Association for Computing Machinery. We propose a novel technique for the automatic design of molds to cast highly complex shapes. The technique generates composite, two-piece molds. Each mold piece is made up of a hard plastic shell and a flexible silicone part. Thanks to the thin, soft, and smartly shaped silicone part, which is kept in place by a hard plastic shell, we can cast objects of unprecedented complexity. An innovative algorithm based on a volumetric analysis defines the layout of the internal cuts in the silicone mold part. Our approach can robustly handle thin protruding features and intertwined topologies that have caused previous methods to fail. We compare our results with state of the art techniques, and we demonstrate the casting of shapes with extremely complex geometry

The making of nickel and nickel-alloy shapes by casting, powder metallurgy, electroforming, chemical vapor deposition, and metal spraying

Casting, powder metallurgy, electroforming, metal spraying, and chemical vapor deposition techniques for producing nickel and nickel-alloy shape

Development of 3D Compression Molded Composite Primary Structure

The work accomplished by the Black Gold team improved upon the carbon fiber compression molding research and information available on the Cal Poly San Luis Obispo campus. The team used the rear suspension rocker arm off a Ventana Alpino mountain bike as a design goal for this project. This research and body of work includes the methods used to design a compression molded part for complex part loading and shape. This extends to the process of choosing an appropriate layup process, in addition to benefits and drawbacks of the use of chopped fibers in compression molding. The research includes the process and information required to build aluminum molds for compression molded parts of complex shape; manufacturing techniques, and suggestions for the use of compression molding carbon fiber. Finally, data is presented which compares the final compression molding results under ultimate and relative stiffness testing to a comparable part made from aluminum. Ultimately, the team found that compression molding proved to be a potential manufacturing alternative. The rocker arms produced by the team were able to withstand a load of up to 800lbs; meeting the teams initial design criteria before experiencing localized fractures. With future iteration, and more focus on design for loading, the process could yield parts which could carry much higher loads. In addition, the use of chopped fiber around the bearings regions was a success, ultimately showing that a combination of chopped and cloth fiber was a useful load carrying combination. Further research in these processes would definitively improve upon the results obtained by the team, and as information regarding compression molding increases the team expects its use to become more popular

Nonterrestrial utilization of materials: Automated space manufacturing facility

Four areas related to the nonterrestrial use of materials are included: (1) material resources needed for feedstock in an orbital manufacturing facility, (2) required initial components of a nonterrestrial manufacturing facility, (3) growth and productive capability of such a facility, and (4) automation and robotics requirements of the facility

Fabrication of Decorative Fluorescent Composite Material

Decorative Composites are the composite materials having artistic characteristics in addition to functional characteristics. It is highly possible that the decorative composites may produce an entire new field on the fibrous composite industry. Natural fiber reinforced composite is gaining attention and considered as an eco-friendly material. Generally cellulosic fibers are used to reinforce the composites. In this paper, we proposed a method for producing artistic composite from artistic fabric by using sisal fiber. In order to expand applications of the fiber reinforced composite, we performed the hand lay-up method for the preparation of mold with the help of themocoul. Then using epoxy resin as matrix we prepared a decorative composite with sisal fiber as reinforced material. To make it more attractive, fluorescent materials have been added which disturbed the curing property of epoxy resin and took a lot more time. But finally we got decorative fluorescent composite materials with desired shape

Using 3D Printing Technology to Teach Cartilage Framework Carving for Ear Reconstruction

Objective: The aim of this study was to determine the validity of using a carvable 3D printed rib model in combination with a 3D printed auricular framework to facilitate the teaching, training and planning of auricular reconstruction

Ultra-Light Bear Canister

A bear canister is the primary tool used by outdoor enthusiasts to protect their food from bears while camping or backpacking. There are many effective products currently on the market, however many are not designed with reduced weight in mind. Hardcore backpackers want to have the lightest gear possible to ease the strain of carrying a large pack for sometimes weeks at a time. Current bear canisters exist that utilize carbon fiber for weight reduction, however they rely on stock carbon tubes and lack engineering analysis, and no competitor has a fully composite bear canister available. Our sponsor, Nick Hellewell, approached our team with a unique challenge to design an ultralight bear canister that could withstand testing requirements set by national parks and weigh under one pound. In a marketplace where niche consumers will pay hundreds of dollars for the lightest backpacking equipment available, an ultra-light bear canister could relieve precious weight, and carry a significant price premium

Hand layup: understanding the manual process

© 2015, © 2015 The Author(s). Published by Taylor & Francis. The hand layup of pre-impregnated woven materials is still a large part of the composite manufacturing industry, requiring the skills and experience of a human workforce to form flat plies into complex shapes. It is capable of producing high performance and complex parts, but can be an expensive and variable process. Despite its importance, there appears to have been very little research into the actual methods and techniques used by workers to manipulate flat sheets of composite material into shape during layup. This work presents the first known detailed study of the approach and techniques used by laminators. Four participants laid up onto 15 different shaped molds that replicated features commonly found on composite components. The actions used in layup were grouped into eight distinct techniques. Use of these techniques across tasks of different geometry, ramp angles, radii and drape path was identified using video analysis techniques from the ergonomics field. This revealed strong links between specific features and techniques, revealing a systematic approach to layup. This has enabled the first step toward producing a design for manufacture knowledge base surrounding hand layup. This could then be used to inform the development of the layup process, improve training methods and assist in the design of future automated solutions

Marshall Space Flight Center Research and Technology Report 2019

Today, our calling to explore is greater than ever before, and here at Marshall Space Flight Centerwe make human deep space exploration possible. A key goal for Artemis is demonstrating and perfecting capabilities on the Moon for technologies needed for humans to get to Mars. This years report features 10 of the Agencys 16 Technology Areas, and I am proud of Marshalls role in creating solutions for so many of these daunting technical challenges. Many of these projects will lead to sustainable in-space architecture for human space exploration that will allow us to travel to the Moon, on to Mars, and beyond. Others are developing new scientific instruments capable of providing an unprecedented glimpse into our universe. NASA has led the charge in space exploration for more than six decades, and through the Artemis program we will help build on our work in low Earth orbit and pave the way to the Moon and Mars. At Marshall, we leverage the skills and interest of the international community to conduct scientific research, develop and demonstrate technology, and train international crews to operate further from Earth for longer periods of time than ever before first at the lunar surface, then on to our next giant leap, human exploration of Mars. While each project in this report seeks to advance new technology and challenge conventions, it is important to recognize the diversity of activities and people supporting our mission. This report not only showcases the Centers capabilities and our partnerships, it also highlights the progress our people have achieved in the past year. These scientists, researchers and innovators are why Marshall and NASA will continue to be a leader in innovation, exploration, and discovery for years to come

Bear Minimum: Ultralight Composite Bear Canister

The ultralight backpacking community needs a strong, easy to use, safe bear canister that is lighter than current market products for trekking in the backcountry. A full design of the lid for the bear canister is to be completed. This includes the locking mechanism to ensure it is bear proof, the interface between the lid and the canister, and the structure of the lid so it passes the strength and weight specifications. The lid, along with the already designed canister body, is to be manufactured with formal documentation. The lid will initially be tested separately and then with the canister body as an assembly. All tests will be to either verify or reject one or more of the design specifications listed later in this document. The overarching goal of the project is to find a balance of two project requirements: making a rigid lid that is, when combined with the canister body, less than 1.3 lbf and still meeting the Interagency Grizzly Bear Committee (IGBC) certification strength requirements