Funded in part by Air Force Research Laboratory Manufacturing Technology Small Business Innovation Research contracts, FOPAT Production is producing breakthrough foam patterns for casting foundries and other manufacturers of aerospace components. The advanced patterns will improve casting processes by replacing wax, a known problematic material, with foam.
Estimates indicate the development will generate $5 million in yearly energy savings, as well as $140 million in productivity, material savings, and scrap reduction.
The work also supports goals of ManTech's Advanced Manufacturing Propulsion Initiative, which seeks to transform the Air Force propulsion supplier base in order both to assure industrial capability and capacity in meeting production demands and to accelerate the transition of advanced technology.
Traditional casting processes and designs are severely limited due to the properties of wax, with high scrap rates resulting from shell cracking and material distortion historically plaguing the industry.
Under a 2-year Department of Energy "Inventions and Innovation" program grant and consecutive (Phase I and II) AF SBIR contracts, FOPAT Production created a new material comprising a proprietary mix of components that react and expand to form foam-casting patterns with smooth-surface finish and excellent dimensional predictability.
These patterns are temperature-stable, energy-efficient, and cost-effective products. Further, they are easily processed using standard-investment casting techniques.
By eliminating wax pattern making--and, thus, wax melt cycles--the new foam patterning method provides significant warfighter benefits. Among these advantages are improved operational readiness for F-135 and F-136 aircraft engines and a cost savings of approximately $13 million for the Joint Strike Fighter.
The technology also supports spiral development, a process further enhancing industrial readiness and effectiveness. FOPAT Production has already moved into a 14,000 sq ft facility and is regularly producing foam patterns for casting foundries and component manufacturers.
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