Freshmade 3D LLC — Department of Defense STTR Phase I: AF20C-TCSO1

Description

Depot sustainment requires rapid solutions to critical tooling needs. The Air Logistics Complex has invested in additive manufacturing systems to support sustainment operations. At Tinker AFB, the Reverse Engineering and Critical Tooling (REACT) Lab has two binder jetting systems: a.) a new sand printer for complex-shaped, precision consumable molds and cores for metal casting and b.) a fine particulate material printer traditionally used for low-strength prototypes. Both of these systems create low-strength green state parts useful for their purposes, but Freshmade 3D has developed a method that can allow those systems to produce functional parts and tooling. Freshmade 3D developed AMClad® which is an Engineered Particulate Composite that starts with binder jetting to create net-shape pre-forms that are then infiltrated and coated to make strong, functional parts. This project lays the groundwork to create high-performance, durable parts for sheet metal form blocks and composite lay-up tools. In Phase I, we intend to identify customer tooling opportunities and requirements, generate mechanical property data, and deliver two exemplar tools with a cost and time analysis.