SBIR-STTR Award

The most-time-consuming and labor-intensive process in any product development is the iteration between design and validation thru physical model building and testing. With ever increasing complexity of modern weapons systems and current political environment, the need to reduce development time and cost has never been greater. Amongst a myriad of techniques that have been introduced, Rapid Prototyping has brought the most significant improvements. Rapid Prototyping (RP) is a new class of model fabrication process that creates a 3-dimensional object directly from a solid CAD file by electronically sectioning the object and physically reconstructing each cross section one layer at a time with minimal human intervention. The technique allows fabrication of models at previously unsurpassed speeds. Despite its success and steady progress over the past 5 years, the state of current RP technology does not allow direct fabrication of fully functional models for more extensive testing. In light of the aforementioned limitations and potential benefits, Helisys proposes a 6 month R&D program aimed at applying innovations in materials, software, and laser optics to the already successful commercial process called Laminated Object Manufacturing (LOM).

Rapid prototyping (RP) is a recently developed CAD-drive fabrication technobgy that has brought the most significant improvement in reducing development time, labor, and cost. Companies are slashing months out of development time by having adapted this burgening technology Despite the accomplishments, the technology is still limited to visualization and design verifications only. The physical properties of parts fabricated by the present RP processes are not sufficiently high for extensive functional testing and tooling. In light of the needs, Helisys has conducted a 6 montb Phase I feasibility program which showed that functional parts and tools could be manufactured directly from a CAD file through LOM. In phase II, Helisys proposes to conduct a 24 month R&D program aimed at advancing the materials and process technologies to the point where composites and metal objects could be fabricated. With Bell Helicopter Textron Inc-, a series of field tests will be conducted to validate the developed technologies. UCLA will develop a comprehensive simulation tool for accurately predicting optimized sets of parameters for the various materials that will be developed in this program. The findings will be used to construct a robust prototype LOM machine capable of bandling a wide variety of materials, includinq metals. If successful, the new LOM technology will allow fabrication of inexpensive models and tools for a wide range of applications, including wind tunnel testing, hydroforming, Stress Pattern Analysis by Thermal Emission (SPATE), and prepreg layup. The reduced prototyping and tooling costs will translate to reduced procurement costs.