A multi-material additive manufacturing approach for space compatible materials was demonstrated using Ultem1010 resin filled with carbon fibers on an isogrid structure and antenna with a conductive silver path. The entire AM process was simulated and predicted the residual stress, thermal and chemical shrinkage, deformation, delamination and damages while accounting for hourglass shaped void formation, surface roughness quality. The simulation was validated through material characterization testing of coupons and a 3 point bend specimen. The simulation was able to predict the strength of the 3D printed part comparable to test. Trade studies identified important process and material parameters and their effect on under service static loading and environmental conditions. This allows OEMs to identify the root cause problem of manufacturing process parameters and to develop plans and techniques to certify the individual parts to meet the performance requirements when parts are acquired through different vendors. The computational tools utilized machine G-Code files to generate the FE model that included a fully coupled thermo-mechanical solution for polymer additive manufacturing with reinforced plastics that can predict the durability and damage tolerance of detailed designs. This paper addresses the multi-scale modeling, and 3D-printing of unfilled and filled ULTEM1010 sample coupons using the developed process parameter for FDM fabrication. Three ULTEM1010 parts were fabricated namely unfilled/filled isogrid and antenna with silver conductive ink deposition. We performed ULTEM1010 multi-scale modeling of: 1) material characterization of unfilled, filled ULTEM 1010 and compared with tests (XZ, and ZX stiffness and strength); 2) determined thermal distribution and shrinkage versus time resulting from process cool down using the developed moving grid methodology for accurate heat distribution prediction; 3) developed isogrid finite element model for thermal and coupled thermal structural analysis to predict as-built residual stress, damage type and location, delamination, and deformation during AM process, and 4) predicted compression proof load on isogrid structure resulting in part stresses, damage types, and service load failure.
展开▼
