Rapid Manufacturing for Forward Deployment and Maintenance

 Industrial Origami, Inc., (IOI) has introduced a new manufacturing paradigm based on precision folding of sheet materials along a patented new hinge that is cut into the material. Using standard CAD packages with IOI’s add-on software, designs are created in 3D CAD and unfolded into one or more planar parts. The flat part design is used to drive a laser cutter, water jet cutter, or CNC punch to cut that part out of the desired material. The processed material is then folded physically into the 3D structure that was originally rendered in 3D CAD with the same 3D precision as the 2D cutting process. Conventional bending, by contrast, introduces enormous errors in fabrication.

This new paradigm allows manufacturing operations to store or ship nearly finished goods in a flat, compact form and fold them up when and where they are needed. Fold-up does not require any capital equipment for light gage materials and very light equipment for heavy plate.

IOI has successfully executed two projects through the NCMS sponsored Rapid Prototyping Technology Advancement (RPTA) group. The first, working with the Trident Refit Facility in Kink’s Bay, Georgia, demonstrated that the Precision Industrial Origami process could be scaled up to heavy plate steel and down to .030 aluminum. The second RPTA project, working with the Technology Insertion group at Tinker Air Force Base, showed how the B-52 silhouette work stands could be replaced with a folded plate design that would be stronger, more rigid, meet or exceed OSHA requirements and scale to any size needed for any Depot. During this project IOI has physically demonstrated a new manufacturing approach to making maintenance structures that have inherently improved forward deployment capabilities because the design files or the cut, flat sheets can be more readily transported in a compact form.

IOI, in conjunction with the Technology Insertion group at Tinker AFB and working with several other Maintenance Depots, is proposing this three phase project that will transfer specific, useful IOI designs and manufacturing techniques to the Maintenance Depots.

PHASE I: BATTLE DAMAGE REPAIR STRUCTURES

IOI has designed and delivered a proof of concept battle damage repair strap and box beam. Made from tempered aluminum, this structure provides a pre-engineered rib that can be formed by hand into a curve that matches the fuselage of the aircraft or other machine to provide strength and attachment points for skin patches over large holes. The objective of this phase is to broaden the size and material range of these structures and to model their structural integrity. Originally inspire by a challenge from the Battle Damage Training Center at Tinker AFB, these devices are general purpose structural repair kits. March 03-August 03.

PHASE II: WORK STAND MANUFACTURING FOR IMPROVED FORWARD DEPLOYMENT AND MAINTENANCE

Extending the previous project sponsored by the RPTA group, IOI will work with the Tinker Aircraft Engineering group to design and fabricate a complete B-52 silhouette work stand system and evaluate it for replacing the existing structures in all five B-52 silhouette bays. April 03-April 04.

PHASE III: HIGH MOBILITY WORK CENTERS

Because Depots must reorganize shop workspaces on an ongoing basis, IOI will work with the Technology Insertion group to create conduit and lighting trusses, foldable carts and foldable fixtures. IOI will scale up a space beam design, first presented at NASA during the original RPTA project, to function as conduit and lighting trusses. These beams can be made as a flat sheet on a metal coil. Depot personnel will then unroll and cut the lengths needed and fold them by hand whenever shop spaces are moved. August 03-October 04.

NCMS Contact: Gary Burkart, (612) 839-4567, gburkart@charter.net