Continued enhancement of Additive Manufactured Foundry-grade Sand Molds

OUSD (R&E) CRITICAL TECHNOLOGY AREA(S): Advanced Materials The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), 22 CFR Parts 120-130, which controls the export and import of defense-related material and services, including export of sensitive technical data, or the Export Administration Regulation (EAR), 15 CFR Parts 730-774, which controls dual use items. Offerors must disclose any proposed use of foreign nationals (FNs), their country(ies) of origin, the type of visa or work permit possessed, and the statement of work (SOW) tasks intended for accomplishment by the FN(s) in accordance with the Announcement. Offerors are advised foreign nationals proposed to perform on this topic may be restricted due to the technical data under US Export Control Laws. OBJECTIVE: Advance the use of Lost-PLA to be able to achieve aerospace grade aluminum castings. Upon completion of the project, Tinker will be able to cheaply deploy investment casting type capabilities within REACT within an easily scalable workflow. DESCRIPTION: -Deploy PLA manufacturing systems within REACT that are compatible with the ATO. -Establish digital workflow to go from a reverse engineered part to a PLA print capable of operating as a casting positive -Establish process controls and facility requirements for the investment and set up of the casting -Perform sufficient testing to demonstrate AMS 2175 quality of Class B or PHASE I: As this is a Direct-to-Phase-II (D2P2) topic, no Phase I awards will be made as a result of this topic. To qualify for this D2P2 topic, the Government expects the applicant(s) to demonstrate feasibility by means of a prior Phase I-type effort that does not constitute work undertaken as part of a prior or ongoing SBIR/STTR funding agreement. Applicant(s) must be able to demonstrate ability to use evaporative casting methodologies (e.g. lost-PLA or lost-foam) previously. PLA or foam tooling manufacturing must be of additive/digital variety. The applicant(s) must be able to provide sufficient data for the government to determine feasibility. PHASE II: -Deploy PLA manufacturing systems within REACT that are compatible with the ATO. -Establish digital workflow to go from a reverse engineered part to a PLA print capable of operating as a casting positive -Establish process controls and facility requirements for the investment and set up of the casting -Perform sufficient testing to demonstrate AMS 2175 quality of Class B or higher PHASE III DUAL USE APPLICATIONS: Output from Phase II will result in a low cost (~$15k-30k) ability for Tinker to expand to lost-PLA casting. Other bases with the ability to melt (e.g. Rock Island Arsenal in the US Army). The ALC will purchase technology using organization (working capital) funds. REFERENCES: AMS 2175; KEYWORDS: Casting; Investment Casting; Lost PLA; Aluminum