Layer-build technology is starting
to gain acceptance as a viable fabrication method to build
functional hardware. This is particularly true for applications
where low-volume or low-rate volume is required since no or only
minimal tooling is required. The introduction of layer-building
into “manufacturing” started with the fabrication of
non-metallic structures for aerospace components and now is
expanding to produce metallic components.
There are several candidate
layer-build technologies capable of producing metallic
components, such as electron beam melting (EBM) manufacturing of
titanium alloys. A description of the process used to produce
Ti-6Al-4V components directly from CAD files will be presented
along with the benefits and limitations of the process. Examples
of components manufactured by EBM will be presented and the
associated mechanical and physical properties presented.
John is the president of CalRAM,
Inc., a small start-up company in Simi Valley, CA, focused on
the rapid manufacturing of metallic components. Prior to forming
CalRAM, John created a wholly-owned Boeing Subsidiary, On Demand
Manufacturing (ODM), where he served as the General Manager.
The purpose of the subsidiary was
to utilize a rapid manufacturing technology, Selective Laser
Sintering, to fabricate aircraft components. ODM fabricated
non-metallic components for the F/A-18 aircraft, UCAV, C-130 and
several other platforms.
John has over twenty years of experience as a program manager
for the Boeing Company, Rockwell International, and Aerojet
where he managed primarily materials and manufacturing
technology programs. In this capacity,
John worked with government
customers, Air Force, NASA, DARPA, and the Army, as well as
primes, to develop the programs and served as the proposal
manager/capture team leader during the capture process.
John served as the principal
contact with the customer and provided the link to corporate
management. Prior to becoming a program manager, he developed
metals and ceramic injection molding technology for Rockwell
International. John has a wide range of experience in materials
and processes technologies.
