COMMITMENT. Manufacturing Technologies to Enable Advanced Munitions. & SOLUTIONS Act like someone s life depends on what we do.

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1 Manufacturing Technologies to Enable Advanced Munitions Giuseppe L. Di Benedetto, Ph.D. Advanced Materials Technology Branch U.S. Army ARDEC Picatinny Arsenal, NJ, USA, UNPARALLELED COMMITMENT & SOLUTIONS Act like someone s life depends on what we do. U.S. ARMY ARMAMENT RESEARCH, DEVELOPMENT & ENGINEERING CENTER

2 CO-AUTHORS Daniel P. Schmidt, David H. Sabanosh, Ryan P. Petillo, James L. Zunino Advanced Materials Technology Branch Jeffrey R. Kraft, Leila Zunino, Thomas C. Thompson Detonation Physics and Experimentation Research Branch, U.S. Army ARDEC, Picatinny Arsenal, NJ

3 Army S&T Performing Organizations Personnel Medical Infrastructure/ Environmental Materiel Strategic Missile Defense Test & Evaluation G-1 HQDA, G-1 Personnel MEDCOM Army Medical Command USACE Army Corps of Engineers AMC Army Materiel Command SMDC Army Space & Missile Defense Command ATEC Army Test & Evaluation Command RDECOM Research, Development & Engineering Command ARL AMRDEC ARDEC CERDEC ECBC NSRDEC TARDEC Army Research Laboratory Aviation & Missile Research, Development & Engineering Command Armaments Research, Development & Engineering Command Communications- Electronics Research, Development & Engineering Command Edgewood Chemical Biological Center Natick Soldier Research, Development & Engineering Command Tank-Automotive Research, Development & Engineering Command 3

4 S&T IN RDECOM RDECs PMs/PEOS ARL Discovery Innovation Advanced Development Engineering & Production Support to Warfighter MEMS TBI Sensor Face-Gear Technology for Block III Apache Translational Neuroscience MRAP Armor XM25 Counter Defilade Target Engagement System 4

5 OPPORTUNITY SPACE There are opportunities for Additive Manufacturing (AM) & Printed Electronics (PE) to impact all Army Systems UAVs, UGVs Logistics Vehicles & Sub- Systems Individual Soldier Protection Repair Parts Communications Command & Controls Missiles/Munitions: Warheads, Fuzes Weapons Components 5

6 WARFIGHTER BENEFITS AM is any process by which digital 3D design data is used to build up a component in layers by depositing material. Integrated & Embedded Electronics Metals AM for Repairs Expeditionary / Battlefield Manufacturing Warfighting Benefits How Examples Topological Optimization More Effective & Lethal Weapon Systems Tailored Solutions for the Mission and Warfighter. Agility of Production Line - New era of supply chain independence Reduced Sustainment Costs and Increased Responsiveness Accelerated Capability Development Ability to manufacture complex shapes and otherwise-impossible designs/components Ability for mission tailorability and mass customization at almost no additional cost Ability to produce only what s needed, where it s needed, when it s needed Ability to make obsolescence obsolete Ability for INNOVATION; novel designs, rapid development, faster transitions Consolidated assemblies Lattice structures Multi-functional materials Embedded sensors Armor Weapons Munitions Unmanned systems Improved field fabrication Good enough & Conditionally Approved parts Environment-independent printers Rapid reverse-engineering Anti-corrosive Anti-degradation materials Urgent needs Rapid response 6

7 ARDEC AM COMPETENCIES Applied Research Technology Development Demo & Prototyping Transition to Production Systems Surveillance Demilitarization Technologies Printed Electronics Metals Polymers Energetics Design Materials Development - Inks, Coatings, Substrates Process Development Characterization Flex Hybrid Electronics Integration Manufacturing Scale-Up Testing Design Powder Synthesis Metals 3DP Machining Mechanical Testing Characterization Post Processing Prototyping / Mfg Design Formulation Materials Development Characterization Testing Qual. & Cert. Support Design Synthesis Formulation Characterization Pilot Manufacturing Munitions Integration Qualification Testing Integration Surveillance 7

8 3-AXIS VS 6-AXIS Linear Movement and Deposition in 3 axes (x, y, z) Ability to operate normal to linear surfaces (NOT curvilinear). Depending on geometry of substrate/part, might require complex, unique fixture to hold in place. Easier to program tool paths. Not capable enough for more complex, unique geometries. Movement and Deposition in 6 axes (x, y, z, a, b, c) Ability to operate normal to linear AND curvilinear surfaces. Often eliminates need for complex fixtures to hold substrate/part. More difficult to program tool paths. Too complex and time consuming for simpler 3-axis design builds. 8

9 MANUFACTURING TECHNOLOGIES TO ENABLE ADVANCED MUNITIONS 9

10 Printed Electronics & Functional Materials WHAT IS IT? Integration of printed functional materials and electronics for new novel munition designs and advanced detonation physics concepts Utilizes COTS printer technology along with the integration of advanced functional materials. WHAT DOES IT OFFER? Printed functional materials allow for a revolutionary new approach to weapon design and use Functional material printing enables low cost schemes for producing multiple warhead responses Allows regain of losses in warhead size due to guidance and range requirements Significantly reduce distribution logistics Enables rapid development and prototyping of solutions for current and emerging threats Partners: Other DOD Elements, DoE Contractors, & Academia TECHNICAL APPROACH: Develop new prototype writable functional material inks and technologies for munition applications. CURRENT CHALLENGE: Award Recipient for Printed Electronics Fab-In-Field Micro-Electro Mechanical Systems (MEMS) Addresses geometric and functional challenges in munition design and fabrication Availability of low cost fabrication methods for advanced concepts 10

11 Printed Electronics & Functional Materials VIDEO HERE!!!! 11

12 MULTI-AXIS MULTIFUNCTIONAL MANUFACTURING PLATFORM M 3 P Camera/inspection tool module FDM extruder tool module Syringe deposition tool module Spray/encapsulant tool module 4-point robe/inspection tool module Router tool module 12

13 40 MM HIGH-G TEST CIRCUIT Leads and Traces Printed Resistors Integrated Interconnects Hybrid Flex Circuit 40 MM Test Rounds 13

14 PROCESS DEVELOPMENT EFFORTS Ag Ink on FR4 Polymer on Foamed Celluloid Conductives Embedded in PLA Conductives on Fabric/Textiles Various Substrates/Geometries Ag Ink on Composite Ag on Kapton & PEEK Polymer on Glass Ag Ink & P-DOT PSS on Polymers Functional Materials on PET Ag Ink on ULTEM Ag on Aluminide Graphene/CNTs on Ag/Kapton High Temp Conductives on Ceramic (PTZ) 14

15 MANUFACTURING TECHNOLOGIES TO ENABLE ADVANCED MUNITIONS 15

16 SUPERSCRYPT SYSTEM The SuperScrypt can deposit on complex curves, or build 3D shapes from scan data. 6-axis Motion Control. Robust hardware allows for +/- 200nm precision. This system includes: Line Scanning Thermoplastic Extrusion (up to 400 ) Thermoset Deposition (0 to 2,000,000cP, with pico-liter control) Ink Deposition 6-Axis Motion Control Tool Switching Pick-n-Place Micro-Milling Potential for future tool developments Conformal Printing Scan-to-Print Tools can be added as needed Fabricate a functioning device 16

17 SUPERSCRYPT SYSTEM VIDEO HERE!!!! 17

18 RESERVE BATTERY INITIATION SYSTEM (RBIS) Conventional PCB - RBIS Flex Hybrid Integration ~ 60% COTS Components Hybrid Printed Iteration Direct Write & Inkjet Components Integrated with COTS Integrated Thermal Reserve Battery with RBIS Hybrid Circuitry Hybrid Printed Flex RBIS < 30% COTS 18

19 SUPERSCRYPT SYSTEM VIDEO HERE!!!! 19

20 NEXT GENERATION HAND GRENADE M67 Grenade 20

21 NEXT GENERATION HAND GRENADE 6-Axis Matls Printing Automation of printed functional materials over a 3-D geometry. Enable innovative designs for future munitions. Issues: Speed, accuracy, tolerance, and cost COST & WEIGHT SAFETY & PERFORMANCE 21

22 MANIPULATION BY ROBOTICS ARMS Modifying the BCN3D Moveo Open Source Robotic Arm for aiding Additive Manufacturing. Low cost option. Designed for 5-axis control, modifying for 6-axis. All structural parts printed in-house. Arduino controlled. Modifying control scheme for our In-House Additive Manufacturing processes. 22

23 MANIPULATION BY ROBOTICS ARMS Controlled Axes Maximum payload Repeatability Horizontal reach Vertical reach Weight 6 axes 24 kg (~53 lb) +/ mm (~0.002 in) 1,730 mm (~68.1 in) 3,089 mm (~121.6 in) 268 kg (~591 lb) 23

24 40MM MUNITION AND M203 GRENADE LAUNCHER TEST FIRE VIDEO HERE!!!! 24

25 Conclusions Manufacturing technologies are critical for the next generation of smart munitions for small and medium caliber applications. U.S. Army ARDEC is investigating and developing techniques to apply printed materials onto complex geometries. Increase performance and reduce the weight and size of a variety of munitions and warheads. The installation and utilization of 6-Axis Deposition Equipment will enable new capabilities for current and future munitions. New equipment being installed and calibrated right now at ARDEC. Through the advancement of printed electronics and additive manufacturing, superior capabilities can be added to current and future military systems. 25

26 Acknowledgements This work was funded by: 26

27 Questions/Comments Giuseppe L. Di Benedetto, Ph.D. Armaments Engineering Analysis & Manufacturing Directorate US Army ARDEC RDAR-MEA-P