Tech Briefs Magazine - May 2023 - 54

SPINOFF
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This hot-fire test of a 3D-printed rocket engine injector was successful, with post-test inspections revealing
the injector remained in such excellent condition and performed so well that it went into
acoustic tests. Now engineers can use DC-AM to design, build, and test parts like this in a virtual environment
created by Sentient Science. (Image: NASA)
Thanks to the Amazon Web Services
high-performance computing that runs
DC-AM, anyone can develop and optimize
any part, building and testing it in a
virtual environment. When it comes to
replacing an existing part design, the
program can quickly determine whether
the new part is going to meet the design
specifications and the intended lifespan
for a particular purpose, explained Melissa
McReynolds, Vice President of automotive
operations at Sentient Science.
The company has several automobile
manufacturers putting the program
through its paces to identify how
3D-printed parts might fit into existing
and future car designs. The program can
be used in any industry that relies on
metal parts, and the Japanese company
Matsuura Machinery is using DC-AM to
provide quality control for its
3D-part-printing arm. And the company
is working with Sentient Science to include
the program in a new 3D printer
that will monitor parts while they're being
created. If a flaw is detected that will
result in a defect, the system will automatically
cease production, remove the
damaged layer, and resume the process.
This new modeling program builds on
the success of the first DigitalClone software,
also built with NASA's help, which
predicts the lifespan of machine components.
New versions, in addition to DC54
AM,
support specific industry needs:
DC-E for engineering, DC-OM for wind
energy, and DC-RM for rail.
Businesses that 3D print parts need to
accurately predict how long a part will
function so they can create maintenance
and replacement schedules without
compromising safety. For them and their
customers, the expertise NASA contributed
to the program adds another level
of quality assurance.
" Through that collaboration with JPL,
we were able to include their knowledge
in creating a product that allows a customer
to do that same type of analysis
without having to acquire the PhD-level
expertise our team has, " said Rios.
The agency benefits from the significant
cost and time reduction compared
to conventional physical testing for new
component designs, materials, and processes.
McEnerney noted that the partnership
with Sentient Science has created
a new resource for " the greater
engineering community. "
" We're looking to continually evolve
and hear new voices, to come up with
new technologies, " said McEnerney. " By
leveraging small businesses, we're going
to get a better outcome for the agency
and for the country. "
For more information, visit https://
spinoff.nasa.gov/Cloning-Metal-Partsfor-Space-and-Earth.
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