Open Competition 3 - Chemistry and Materials

Rapid, Ultraprecision Direct Metal Deposition Technology

Sponsor: The POM Group, Inc.

• Project Performance Period: 9/1/2004 - 8/31/2008
• Total project (est.): $12,457,476.00
• Requested ATP funds: $6,147,055.00

Tools, dies, and molds are used widely to make plastic and metal parts for the automotive, medical, electronics, and other industries. The U.S. tool and die industry is under intense competitive pressure because many large manufacturers are moving overseas to reduce labor costs, while taking their supply chains with them. Advances in manufacturing technology and productivity are needed to help offset the U.S. cost disadvantage and maintain leadership in high-precision, high-accuracy tooling. The POM Group with joint-venture partners Nuvonyz Inc. (Bridgeton, Mo.), and Stellite Coatings (Goshen, Ind.) plans a four-year project to develop direct-metal deposition and surface finishing technologies for an innovative high-speed process for making tools and dies. The proposed approach will reduce greatly the time needed to produce complex tools while also improving their quality and mechanical properties. The deposition process involves forming shapes by injecting metal powders into a melt generated by a high-powered, fiber-coupled diode laser. A nanoscale machining process will be developed to achieve a super-finished surface quality, and optical feedback technology will be used for closed-loop control of metal deposition. In addition, advanced sensing capabilities will be developed for real-time control of thermal conditions to minimize property variations and distortions of the deposited part. Integration of all these components into a single working unit presents substantial technical risk. The S.M. Wu Manufacturing Research Center at the University of Michigan (Ann Arbor, Mich.) will develop precision machining and process monitoring and control. The ATP funding will accelerate development of this new technology by at least five years. If successful, the project will enhance the productivity and efficiency of the U.S. tool and die industry by reducing the time to market, simplifying manufacturing, and extending tool life. The technology also will make "mobile die repair" possible, such that repair equipment can be brought to the die, minimizing costly production downtime and die transportation costs. Initial applications will include plastic injection molding, hot forging, and metal stamping. The new technology also could be useful for making automotive engines and other components, finishing medical products such as prosthetic devices, and making replacement parts on the battlefield for defense applications.

For project information:

Roger Parson, (248) 390-6617
rogerp@combine.com

Active Project Participants

• Nuvonyx, Inc. (Bridgeton, MO)
  [Original, Active Member]
  
• Stellite Coatings (Goshen, IN)
  [Original, Active Member]
  

ATP Project Manager

Jean-Louis Staudenmann, (301) 975-4866
jstaudenmann@nist.gov