Reliability Centered Additive Manufacturing Design Framework Navy SBIR FY2015.2 Sol No.: Navy SBIR FY2015.2 Topic No.: N152-109 Topic Title: Reliability Centered Additive Manufacturing Design Framework Proposal No.: N152-109-0608 Firm: Weidlinger Associates, Inc. 40 Wall Street 19th Floor New York, New York 10005-1304 Contact: Heather Reed Phone: (212) 367-2951 Web Site: http://www.wai.com Abstract: Additive manufacturing is quickly maturing as a mainstream production method and will enable the engineering of highly complex, design-optimized components. To fully exploit the benefits and possibilities of AM, the processes and challenges associated with the new opportunities need to be fully understood, and the reliability of the components included as part of the design process. The proposed Reliability-Centered Additive Manufacturing Computational Design Framework (RCAM CDF) describes a multi-module approach for ensuring reliability of complex, AM components. The RCAM CDF incorporates high-fidelity modeling and simulation of the four modules representing the major phases of a component�s life: Design Optimization, AM Process, Monitoring, and Repair. By simulating each module, a user can include reliability directly into the component�s design. The proposed solution will demonstrate the �Monitoring� module of the RCAM CDF on a small component (with an embedded, hidden defect), representative of a complex heat exchanger. The heat exchanger component will be inspected by model-based, ultrasonic testing (UT), in which physical inspection data and simulated inspection data are coupled within a Bayesian analysis to characterize and quantify the uncertainty surrounding the defect. Uncertainty quantification of the defect is important as it directly affects the reliability of the component. Benefits: The proposed design framework (and associated software tools) has wide reaching commercial applications, across the defense, aerospace, naval, marine, automotive, oil/gas, and manufacturing industries. It will allow widespread adoption of additive manufacturing for part production, by accurately quantifying and predicting part reliability. The holistic design framework � from initial design through production, operation, and repair � accounts for the entire lifecycle of the product, and builds reliability into the design. This framework effectively solves the biggest challenge facing widespread adoption of additive manufacturing: certification and qualification of components. By teaming with the largest and most established manufacturer of 3D printing systems, we expect to achieve optimal market reach and presence. Return