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AlphaSTAR & Raytheon present ‘Qualification of an AM Missile’ at AMUG

LONG BEACH, CALIFORNIA, (2/27/2019) – Collaborating on a Missile Defense Agency Phase II contract,
AlphaSTAR and Raytheon set out to predict the Additive Manufacturing Process and Service Loading of an
as-built 3D printed part. Using an ICMSE framework, and feeding through a building block Verification,
Validation and Accreditation (VVA), the teams set out a goal of hashing out many part issues before print,
thus saving time, lowering risk and reducing scrap rate.

This program has been co-led by Cody Godines, Structures Group Lead at AlphaSTAR and Senior Mechanical
Engineers, Isis Roche-Rios and Alicia Leslie of Raytheon. “With the promise that Laser Powder Bed Fusion
(LPBF) has in additive manufacturing, there are also major pitfalls – such as: defects, unmet net shape,
high warpage, residual stress and surface roughness, void formations and inconsistent density just to name
a few. We were able to simulate all of these with the GENOA 3DP tool within the Ansys framework before
printing”, says Godines.

Another key component of a successful build was the prediction of Thermal History, Material State, and
Process Maps, which are used to predict all important phenomena and regions. ‘We found that knowing all
of this information beforehand sets up for a successful final simulation with multi objective optimization of
the component and support structure to minimize mass and scrap rate while minimizing the pitfalls of AM”,
added Leslie.

To learn more about the success and further findings of this MDA Phase II Program, join Cody & Alicia in
the International Ballroom at 4:30pm on Monday April 1st for a full presentation.

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