Scalable Design for Manufacturing, Modeling Optimization for Additive Manufacturing - MSC P4382
Navy SBIR FY2018.1

Sol No.: Navy SBIR FY2018.1
Topic No.: N181-094
Topic Title: Scalable Design for Manufacturing, Modeling Optimization for Additive Manufacturing - MSC P4382
Proposal No.: N181-094-0875
Firm: Materials Sciences Corporation
135 Rock Road
Horsham, Pennsylvania 19044
Contact: Devlin Hayduke
Phone: (215) 542-8400
Web Site:
Abstract: With recent advances in additive manufacturing (AM) technologies, components and structures that can benefit from cellular design and optimization are now being realized. Materials Sciences Corporation (MSC) has developed and demonstrated the design and analysis tools needed to optimize cellular (lattice) structures that exploit state-of-the-art manufacturing processes and tailor the frequency response of missile components and associated structures while minimizing weight. Despite these advances, considerable research is required to develop robust structural components for missile structures. In particular, optimization of the strength of cellular structures and verification of their performance via experiments is needed. In response to this need, the proposed research will focus on development of an integrated framework of design, analysis, and test and evaluation methodologies to design structural components using a lattice (cellular) design. Particular attention will be paid to optimization of unit cell architectures and lattice networks for strength, e.g., local yielding, local buckling, global buckling, etc. The result of this research will be a modeling framework of design and analysis for the development of scalable lattice (or cellular) architectures to optimize the weight, dynamic response and robustness of structural components for missile applications.
Benefits: The primary product anticipated as a result of this SBIR program, i.e., Phase II, is a modeling framework that can optimize missile structural component design using various scales of lattice (or cellular) designs to minimize weight; achieve a required stiffness, strength, and reliability; and meet system structural and dynamic performance objectives with confidence levels. It is believed that proposed technology has the potential to be applied to future upgrades to existing legacy strategic systems as well as to future strategic ballistic systems. A restricted version of framework is targeted for the global, industrial AM market for packaging with commercial design and analysis software, e.g. ANSYS. It is anticipated that the proposed modeling framework will help address some key issues such as the accuracy, reproducibility, and reliability of AM, and the verification and validation challenges that remain for qualification in order to realize cost savings potential of AM.