Defense

美国海军Research Lab engineers 3D print functional lightweight cylindrical antenna arrays

工程师在美国海军Research Laboratory(NRL)已部署了3D打印机来制造优化的天线组件,这可能是推进的关键美国海军的雷达监测功能。

Utilizing 3D printing, the engineers were able to create cylindrical arrays at a lower cost and with reduced lead times compared to those incurred using conventional specialized equipment. The resulting parts also proved to be significantly lighter than previous iterations, potentially lending them new end-use navigational or defense applications.

NRL电气工程师Anna Stumme说:“ 3D打印是一种生产快速原型并以最低成本快速进行多次设计迭代的方法。”“印刷零件的轻质重量也使我们能够将技术带入新的应用程序,在这些应用程序中,用来限制我们的固体金属零件的重量重。”

工程师Anna Stumme和她的NRL同事有3D打印的优化圆柱阵列(如图)。通过NRL的照片。

Servicing naval antenna arrays

While operating at sea, naval ships rely heavily on their radars, not only as a means of maritime navigation, but monitoring the movements of potential aggressors from a distance. These critical systems are powered by arrays composed of interconnected antennas, but they are often subject to breakage, necessitating their rapid replacement.

目前,此类停止零件是从金属中订购的或错综复杂的,这一过程可能需要数周才能完成。另一方面,使用3D打印机,Stumme和她的NRL同事发现,由于所需的加工和组装时间的减少,现在可以在几个小时内制造诸如圆柱形阵列之类的组件。

但是,虽然外国国防军,例如荷兰海军采用了Intamsys 3D打印to fabricate spares on-demand, the NRL don’t consider this to be realistic yet. In fact, the engineers maintain that the technology has greater potential in rapidly iterating new designs, something they’ve put to good use with their novel antenna array.

Stumme解释说:“我们并不是要说我们需要3D打印所有东西并将其放在船上,因为那是不现实的。”“我们不一定知道在这种环境中它将如何保持。对我们来说,这是一种在短时间内测试更多设计迭代的方法。”

The 3D printed cylindrical array (pictured top) proved to be more compact than the original (pictured middle). Photo via the NRL.

3D打印NRL天线

NRL团队在2019年天线应用研讨会上获得了最初的研究奖,因此选择如何使用3D打印来优化相关零件的重量。首先,工程师在实验室的自主系统研究设施中对它们进行电镀之前,制作了一组尼龙原型。

During the process, the researchers were able to add a thin metal layer to each part, providing them with the conductive surface necessary for relaying applications. Once ready, the prototypes underwent surface roughness characterization tests, which effectively allowed the team to assess the impact of exterior finish on their performance.

“表面粗糙度对于波导和天线很重要,因为它会导致散射损失并导致效率较低的天线,”应用材料和系统部分的负责人Nick Charipar解释说。“天线辐射并接收波浪。因此,如果波浪沿粗糙的表面延伸,它会变形,并且能量可能不会流到您想要的地方。”

After the initial tests, the NRL’s Radar Division installed the components to see how they affected radar functionality, finding that each 3D printer’s characteristics affected the device’s performance. As a result, the team concluded that if an optimized parameter set can be identified, then spare arrays could be rapidly produced anywhere in the world.

今年晚些时候,Stumme和NRL船员打算通过对原型圆柱阵列光圈进行现场测试来结束他们的研究,将其集成到X波段监视雷达中。阵列,用于提供360o对小型船的可见性,将使用轻质光纤打印3D,有可能授予它们增强的热性能。

美国海军和海上印刷

The US Navy has long recognized the potential of 3D printed parts, and invested heavily in both researching them and their end-use application.

Most recently, theUS Naval Postgraduate School(NP)成为第一个安装的施乐的新Elemx液体金属3D打印机。The NPS has effectively entered into a collaboration with Xerox that will see it attempt to develop new ways of fabricating parts on-demand for deployment across the US Armed Forces.

美国海军的海军系统司令部(NAVSEA) division has also awarded funding to seven研发计划可能会节省2.5亿美元的成本。At an initial outlay of just $8.2 million, the part optimization initiatives potentially represent a highly efficient way of reducing the maintenance needed onboard naval vessels.

在其他地方,科学家驻扎在Naval Surface Warfare Center已经开发并申请了新颖的可生物降解3D打印材料。团队认为,将来可以部署其新聚合物,以创建水下设备,例如无人驾驶或自动水下车辆(UUV)。

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Featured image shows Anna Stumme making adjustments to an antenna array inside the anechoic chamber at the NRL. Photo via the NRL.