Additive Manufacturing 3 D Printing at Fermilab Brian

Additive Manufacturing (3 D Printing) at Fermilab Brian Hartsell Engineers Retreat 20 Feb 2019

Outline • What is Additive Manufacturing? • Current AM at lab • Looking to the future 2

A few things first. . • This presentation is from the point of view of a mechanical engineer. – Applicable to many disciplines. • Many of the parts will be displayed during the networking session on a table in the cafeteria. – Come find us with additional questions, ideas, comments that we can’t get to during the talk. 3

What is Additive Manufacturing? • Additive manufacturing is the process of making a part a layer at a time. Also called 3 D printing. – Fused Filament Fabrication (FFF), shown in video • Also labeled FDM, proprietary term. – – – 4 Powder Bed Fusion Directed Energy Deposition Material Jetting Binder Jetting Sheet Lamination Vat Polymerization

AM Use at Fermilab • Common question – what 3 D printers are available at the lab? • Table on the following slides is courtesy of Rick Reinert. • This has been added to Teamcenter: – ED 009726 • Please check out, provide updates, and check back in! 5

AM Use at Fermilab Divison Description Technology Contact AD - Accelerator Division Target Systems Department Ultimaker 2+ Keith Anderson Extended FFF anderk@fnal. gov Keith Anderson Hyrel 30 M FFF anderk@fnal. gov Keith Anderson Form 2 SLA anderk@fnal. gov Mechanical Support Department Ultimaker 2+ Extended FFF Fusion 3 F 400 HFR FFF Prusa I 3 MK 3 FFF Kris A Anderson kaa@fnal. gov Comments Heated build chamber for high temp plastics 12" cube build volume with high flow rate hotend Qty 3, printer farm APS-TD - Technical Division Stratasys F 170 6 FFF Jodie Coghill coghill@fnal. gov 10" cube build volume

AM Use at Fermilab Division. Description Type Contact Comments FESS - Facilities Engineering Services Section Makerbot FFF Jim Niehoff - niehoff@fnal. gov PPD - Particle Physics Division Mechanical Engineering Makerbot Replicator 2 FFF Rick Reinert - rreinert@fnal. gov AON 3 D M 2 Rick Reinert - rreinert@fnal. gov FFF Electrical Engineering Makerbot Replicator Gen 5 FFF Ultimaker 2 7 FFF Dave Huffman - huffman@fnal. gov, Mike Utes - utes@fnal. gov, Paul Rubinov - rubinov@fnal. gov 5 th floor crossover of Wilson Hall BEG building near break room 18 x 25" build area, heated chamber for high temp plastics

AD/MSD ‘Printer Cave’ 8

AM Use at Fermilab • Outside service bureaus: – C-ideas – Protolabs • Examples in the case studies from both of these companies. 9

Case Studies – AD/TSD (Target Service Department) • Most work within TSD has been utilizing FDM and SLA of plastic materials - PLA, ABS, SLA resins, and Ultem • Significant cost and schedule savings in the following areas: – Remote inspection hardware used in very high radiation areas – Rapid prototype assembly tooling – Wind tunnel testing and optimization of air diverter development for Nu. MI/NOv. A 1 MW horn stripline cooling considerations – Hot cell PIE (Post Irradiation Examination) of NOv. A target – Hot cell custom end-of-arm telemanipulator tooling – Quick turnaround beam position diagnostic for neutrino target – Pion production study at CERN NA 61 (aggressive schedule dependent) – Material capsule holders for Hi. Rad. Mat collaboration 10

Remote inspection hardware - FFF Utilizing PLA Filament Design and photo courtesy of Keith Anderson End of Arm Tooling (EOAT) for telemanipulator assisted flange R&R 11

NOv. A PIE of Target TA-01 Fin Integrity in Target Canister Plastic Resins Utilizing FDM and SLA Design and photo courtesy of Keith Anderson Quick turnaround custom tooling to fixture 2 mini-cameras for remote viewing along the target length with multiple mounting locations 12

Inspection Robot - FFF and SLA – Ulti. Maker and Form 2 Design and photo courtesy of Keith Anderson • Total Cost less Dome Camera ~$110 (belts cost $25/ea) • Compare to the $18 k cost of an existing tactical robot where contaminated track replacement cost $800 13

Service Bureaus Mu 2 e Target Robot Simulated Window Flange • Fabricated by C Ideas • Cost $1500 with 1 week Delivery • Compare to Al flange cost of $9500 and 6 week delivery 14

Service Bureaus Material Capsule Holders for Beamline Irradiation Characterization of High Power Target Materials --Hi. Rad. Mat / Ra. DIATE Collaboration Photo courtesy Keith Anderson 15 - Required 120 holders of varying sizes and complexity - Ultem holders produced by Service Bureau (C-Ideas) using Ultem for a cost of $25/ea. for entire holder - Quick turnaround - Aluminum holders cost $158/ea. Per ½ holder

Case Studies – AD/MSD High Voltage Feedthrough Mockup • Used a transparent 3 D printed mockup of a high voltage feedthrough to evaluate how well Fluorinert flows and mixes in the feedthrough. • Many more AD/MSD examples here. Images courtesy Matt Alvarez 16

Alignment/Adjustment prototypes Prototypes can easily be made to help find potential issues or to explain a concept. Images courtesy Kris A. Anderson 17

Protective covers Custom covers can be easily made to protect sensitive components. 18

Looking to the future • Investigate enabling technologies – Undertake a study to benchmark AM technologies for improvements in: • Cost • Schedule • Advancing technology – Requires scope of effort and funding – Examples for consideration: • Investment casting • Solid state additive manufacturing – Fabrisonic, embedded sensors • Near net shape manufacturing 19

Looking to the future • Identify and advance “disruptive technologies”: – Binder jetting with multiple materials • Creation of ‘loaded’ neutrino targets to optimize pion yield – Custom Tungsten formulations for high density targets (Mu 2 e) – Your ideas! 20

Thanks! • Contributions from many people: – – – Kris E. Anderson Keith Anderson Kris A. Anderson Rick Reinert Jesse Batko Matt Alvarez • Backup and additional material after this point 21

Mu 2 e Target Prototype • Full-scale 3 D printed assembly of the Mu 2 e target was used to aid physicists and engineers in spotting potential design issues. 22

Service Bureaus Ultem Shipping Container for Hi. Rad. Mat irradiation Samples Custom geometry 23