As researchers at Picatinny Arsenal explore the potential for 3-dimensional printing, they envision the possible to embed a radio antenna at the side of a Soldier’s helmet, or print sensors directly onto a weapon and even an editorial of clothing.
Over the past few years, advancements in 3D printing have enabled scientists to print items starting from body organs to candy.
At Picatinny, scientists and engineers are using additive manufacturing and 3D printing to print electronics, weapon components, and coaching models.
Additive manufacturing, which incorporates 3D printing, lets engineers create three-dimensional solid objects in response to digital models, explained James Zunino, Materials Engineer and Printed Electronics, Energetic, Materials, & Sensors, or PEEMS, Co-Chair.
The printers work by means of lasers or another heat source to meld gypsum, metal powders, plastic filaments or other materials “built” layer-by-layer to create tangible 3D objects.
At the leading edge of Zunino’s 3D research is electronic printing — using an ink-jet printer to print electronics, inclusive of munitions antennas, fuze elements and batteries.
Inks that could conduct electric current, together with silver, are printed in layers onto a movie surface, creating conductors, semiconductors or resistors.
RADIO ANTENNA ON HELMET
This process allows engineers to potentially print sensors directly onto a weapon or an editorial of clothing. For example, a radio antenna made from silver nanoparticles printed onto a versatile polyimide substrate may be embedded right into a Soldier’s helmet, replacing the antenna that currently attaches to the headgear. Or, electronics may well be imprinted on the side of artillery, freeing up space contained in the round.
This ability allows printed electronics to take advantage of space more efficiently than conventionally made electronics.
Also, electronics created with 3D prints generate less waste.
“Instead of getting to machine out the groves and put the sensor and the wires within the model, i will be able to just use our printers to print electronics onto the model so that they are already embedded,” Zunino said.
“With printed electronics versus conventional you’re not chemically etching away the entire material, you’re printing them how you want them. It’s more environmentally friendly, it’s cheaper, and it’s more time efficient.”
The electronics is also outfitted with reactive sensors, inclusive of sensors that modify properties inside the presence of anthrax to detect and warn of the chemical’s presence.
Engineers on the Armament Research, Development and Engineering Center are usually asked to create training pieces which might be used as aides for Soldiers.
“You can actually print a massive version of a fuze mechanism to turn the internal workings,” Zunino said. “You can quickly and affordably try different designs and alter parts. Instead of machining and wasting all that material, we will print them or even put electronics inside.
“You can input the 3D model into the printer, remove a forty five-degree slice and print it out,” he continued. “With our color printer it is going to be printed in the whole right colors and feature the correct markings, so that you have a pleasant training aide.”
The engineers also are capable of quickly fabricate items including the wings of an unmanned aerial vehicle, referred to as a UAV.
PRINTING POTENTIAL PROVIDES GREATER FLEXIBILITY
Currently, there’s no current solution to create a UAV wing out of 1 sheet of metal since the holes for wiring are so intricate. The wings are actually made with two pieces which are sealed together. But with 3D printing, engineers can place each of the holes while the piece is being created.
Wires and printed electronics may also be embedded into the wings as they’re created at the 3D printer.
“You can print UAV wings with the electronics, antennas and sensors in it in order that when you’re done it’s all embedded in a single encapsulated system,” Zunino said.
“It functions an analogous way, but you don’t need to worry about learn how to seal it, the way to package it, find out how to glue it in. You only embed it inside using additive manufacturing techniques,” he said.
One reason 3D printing has most potential is as it is very efficient. Items may be printed in an issue of minutes or hours looking on the complexity of the design. This makes it ideal for prototyping and coffee-rate production.
“I could test a design on a 3D printer using a less expensive material,” Zunino said. “Once i do know it really works and my holes are good, i will go print it on a metals printer that uses stainless-steel or titanium. So it’s cost savings, since you don’t need to buy metal in bulk. We are able to try varieties of materials. 3D printing allows us to inexpensively test a similar design in numerous different materials and spot how they perform.”
3D TECHNOLOGY ADAPTED FOR COMBAT
In the near future, Picatinny scientists hope they are going to be ready to print and assemble entire weapon systems in a single manufacturing cube. As an example, a whole claymore mine can be printed and assembled in a single machine by various tools and printing processes.
Zunino said it will even be beneficial for deployed Soldiers to have 3D scanners to scan a broken part, then send engineers the file from which engineers can make a brand new one.
“Ideally we’d have the warriors have their very own 3D printers inside the field so they can make their very own part to hang them over until we send them the part. Normally, in the event that they broke a bracket, it could actually take two or three weeks to exchange it.”
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