SAMPE Journal - November/December 2016 - 59
Feature Article
Process Descriptions
Manufacturing the tool using AM required three steps:
design, print, and machine. The 3 hours of design
time includes generating the tool geometry, print path,
and machining tool path. Although the print time was
approximately 15 minutes, one hour of machine time
is used in the analysis to allow for set-up time. It is
assumed that machine time on an AM machine capable
of processing carbon fiber-reinforced polymers can be
purchased for $200 per hour. This is an estimate and
may not currently be the case since very few of these
machines exist in the marketplace. However, it is judged
to be a good working number. One hour of machining
time at $250 per hour is used and leaves adequate setup time.
The process for making the same A-frame tool from
carbon fiber involves four steps: design, prepare tooling
board, machine the master, and layup and cure tool.
The 5 hours of design time includes generating the tool
geometry and machining tool path. One hour is given
for cutting and bonding tooling board estimated to cost
$1400 per cubic foot. Machining the master is estimated
to take 1.5 hours at $250 per hour. Laying up and curing
the tool are assumed to take 4 hours at $50 per hour
utilizing ¾ pound of tooling prepreg at $100 per pound.
This last step likely underestimates the real cost as
autoclave cure cycles are costly, and a post cure is often
required for carbon fiber tools. In addition, it is assumed
that no backup structure is required for this tool. For
larger tools, backup structure must be machined and
bonded to the facesheet, adding significant costs. Figure
6 and Tables 1 and 2 summarize the two methods and
compare the final costs. Cost savings of approximately
50% were achieved by utilizing AM to manufacture the
tool.
Figure 6. Process steps and inputs for manufacturing the A-frame tool using AM and a traditional carbon fiber tool manufacturing
process.
SAMPE Journal, Volume 52, No. 6, November/December 2016
59
Table of Contents for the Digital Edition of SAMPE Journal - November/December 2016
Contents
SAMPE Journal - November/December 2016 - Cover1
SAMPE Journal - November/December 2016 - Cover2
SAMPE Journal - November/December 2016 - Contents
SAMPE Journal - November/December 2016 - 2
SAMPE Journal - November/December 2016 - 3
SAMPE Journal - November/December 2016 - 4
SAMPE Journal - November/December 2016 - 5
SAMPE Journal - November/December 2016 - 6
SAMPE Journal - November/December 2016 - 7
SAMPE Journal - November/December 2016 - 8
SAMPE Journal - November/December 2016 - 9
SAMPE Journal - November/December 2016 - 10
SAMPE Journal - November/December 2016 - 11
SAMPE Journal - November/December 2016 - 12
SAMPE Journal - November/December 2016 - 13
SAMPE Journal - November/December 2016 - 14
SAMPE Journal - November/December 2016 - 15
SAMPE Journal - November/December 2016 - 16
SAMPE Journal - November/December 2016 - 17
SAMPE Journal - November/December 2016 - 18
SAMPE Journal - November/December 2016 - 19
SAMPE Journal - November/December 2016 - 20
SAMPE Journal - November/December 2016 - 21
SAMPE Journal - November/December 2016 - 22
SAMPE Journal - November/December 2016 - 23
SAMPE Journal - November/December 2016 - 24
SAMPE Journal - November/December 2016 - 25
SAMPE Journal - November/December 2016 - 26
SAMPE Journal - November/December 2016 - 27
SAMPE Journal - November/December 2016 - 28
SAMPE Journal - November/December 2016 - 29
SAMPE Journal - November/December 2016 - 30
SAMPE Journal - November/December 2016 - 31
SAMPE Journal - November/December 2016 - 32
SAMPE Journal - November/December 2016 - 33
SAMPE Journal - November/December 2016 - 34
SAMPE Journal - November/December 2016 - 35
SAMPE Journal - November/December 2016 - 36
SAMPE Journal - November/December 2016 - 37
SAMPE Journal - November/December 2016 - 38
SAMPE Journal - November/December 2016 - 39
SAMPE Journal - November/December 2016 - 40
SAMPE Journal - November/December 2016 - 41
SAMPE Journal - November/December 2016 - 42
SAMPE Journal - November/December 2016 - 43
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SAMPE Journal - November/December 2016 - 72
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