Accelerating Adoption of Large-Format Additive Manufacturing in Aerospace Tooling

Ascent Aerospace is a mid-sized industrial business that specializes in the manufacturing of aerospace tooling and capital equipment. Due to the nature of the industry, this results in a high mix, low volume production environment where quality and precision are important to the customer. In 2020, just prior to the COVID-19 global pandemic, Ascent made an investment in additive manufacturing technology by purchasing a Large Scale Additive Manufacturing Machine (LSAM) from Thermwood Corporation. The LSAM serves a novel purpose in Ascent’s product portfolio by allowing it to fill customer needs for tools with a quicker turn time and/or lower cost without the strict requirements and high quality standards of Invar or other metal or composite tools. This thesis begins by reviewing the current state of Ascent Aerospace and the commercial aerospace tooling market, followed by an overview of Ascent’s current product portfolio and how the LSAM fits in. Next, an overview of the finite element modeling procedures to ensure adequate performance from a static and thermal loading perspective is roadmapped. Subsequently, a proposed alternate build process that can make LSAM-printed tools a more competitive choice for customers is described, followed by some miscellaneous operational initiatives, results, and conclusions. Taken as a whole, this thesis can serve as a guideline to companies intending to roll out 3d printing or other nascent technologies to broaden its product portfolio.

Name thesis:degree_name

Master

Department dc:contributor.department

Massachusetts Institute of Technology. Department of Aeronautics and Astronautics

Grantor dc:publisher

Massachusetts Institute of Technology

Year dc:date.issued

2022

Author dc:creator

• Stehr, Connor

Advisors dc:contributor.advisor

• Carrier, John
• Hansman, R. John

Statement dc:rights

• In Copyright - Educational Use Permitted
• Copyright retained by author(s)

Licence dc:rights.uri

• https://rightsstatements.org/page/InC-EDU/1.0/

Handle dc:identifier.uri

https://hdl.handle.net/1721.1/146649

OAI identifier oai:identifier

oai:dspace.mit.edu:1721.1/146649