Supply Chain Independent SolidStir® Additive Manufacturing

Advanced/Additive Manufacturing

Winning on the rapidly evolving battlefield requires warfighters to quickly adapt to changing conditions and timely access to deployable assets that are combat-ready and capable. It is also equally important to ensure continuous availability of defense assets during wartime to sustain the hard-fought wins. The defense manufacturing supply chain has been the backbone of US defense forces; however, a depleting manufacturing base for large castings and forgings poses a serious vulnerability for sustainment. Building additional capacity for casting and forging to fulfill US defense needs is not attractive for new investments as the manufacturing requirements are high-mix-low-volume- components. Current advancements in large-scale metal 3D printing have been identified to fill the current gaps in the US manufacturing supply chain. However, the currently available 3D printing methods are slow, capital intensive, heavily relying on specific feedstocks, and are not suitable for rapid expansion. To fulfil these needs, Enabled Engineering has developed, demonstrated, and is commercializing a novel, friction stir welding based solid-state additive manufacturing technology, known as SolidStir® Additive Manufacturing (AM).

SolidStir® AM is rapidly expandable using existing subtractive manufacturing machines and workforce, 50% more economical than the current best alternatives, suitable for scaling up and down, and most importantly, self-reliant for feedstock as it can use old parts and battlefield scrap as feedstock. Enabled Engineering’s systems can be mounted on any existing computer numerical control (CNC) machine and located on the back of a vehicle or the deck of a ship or in an airplane hold. It can even be miniaturized to mount on industrial robots for solid-state repair applications. The feedstock size and shape are flexible. In addition, the system can be set up for continuous feeding. Using SolidStir®, the resultant parts have the same or improved material properties when compared to the original parts due to dynamically recrystallized microstructure. The system is designed for high build rates using lubricant-free manufacturing. Scaling the system down in size is one challenge while having it large enough to accept reasonably sized cut-up parts. Enabled Engineering can make these trades and develop a robust system capable of supporting the DOD in challenging locations. Enabled Engineering has demonstrated using cut-up aluminum parts through our research and development feeding system, resulting in manufactured components as shown in our video for this competition. The technology is at a MRL of 7 for a range of aluminum alloys. It is ready to demonstrate in the field. The solid-state nature of the process allows AM of components using high strength aluminum alloys that are used for ground vehicle armors and airframe structures.

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