College - Author 1
College of Engineering
Department - Author 1
Mechanical Engineering Department
Degree Name - Author 1
BS in Mechanical Engineering
College - Author 2
College of Engineering
Department - Author 2
Mechanical Engineering Department
Degree - Author 2
BS in Mechanical Engineering
College - Author 3
College of Engineering
Department - Author 3
Mechanical Engineering Department
Degree - Author 3
BS in Mechanical Engineering
College - Author 4
College of Engineering
Department - Author 4
Mechanical Engineering Department
Degree - Author 4
BS in Mechanical Engineering
Date
6-2024
Primary Advisor
Hyeonik Song, College of Engineering, Mechanical Engineering Department
Abstract/Summary
Metal additive manufacturing, utilized by Parker Aerospace’s Exotic Metals Forming Division, enables the fabrication of intricately designed metal parts that pose significant machining challenges. This technology uses metal powder melted by a laser or electron beam to produce parts, but excess powder often becomes trapped within internal passageways due to complex geometries. Traditional methods like compressed air, vacuum processes, and manual banging are inadequate for effective powder removal. Consequently, an innovative solution is necessary. The designed solution utilizes a pneumatic motor to vibrate the printed part to break up or remove excess powder and was tested both quantitatively and qualitatively, proving more effective than current methods and meeting project specifications yet still removing over 98% of the powder. Despite manufacturing and procurement challenges, the project demonstrated a viable powder removal solution for additively manufactured parts at a significantly reduced cost, well under the $5000 target budget. Recommendations for future iterations include tighter tolerances, motorized rotation, safety enhancements, and additional vibratory power, ultimately contributing to the safety and efficiency of additive manufacturing processes in the aerospace industry.
URL: https://digitalcommons.calpoly.edu/mesp/771
Project Video
ME_S2023_F76_Poster.pdf (1633 kB)
Project Poster
ME_S2023_F76_SOW.pdf (2460 kB)
Scope of Work
ME_S2023_F76_PDR.pdf (3768 kB)
Preliminary Design Review
ME_S2023_F76_CDR.pdf (5380 kB)
Critical Design Review
ME_S2023_F76_Drawings.pdf (3016 kB)
Drawing Package