Project number
25010
Organization
DMAFB 309 AMARG, supported by the Craig M Berge Dean's Community Fund
Offering
ENGR498-F2024-S2025
The 309th Aerospace Maintenance and Regeneration Group (AMARG) at Davis-Monthan Air Force Base oversees a “boneyard” of decommissioned military aircraft. These aircraft sit on large wooden modules in storage. The modules are effective but outdated. In this multifaceted project, the team conducted a life cycle study on the current modules, developed a novel additive-manufactured replacement for the block, and reported on the feasibility of replacing the current modules with the
new design.
The team first explored the cost of materials, production and implementation of the current modules. One of the key findings was that the current wooden module was designed under the limitations of additive manufacturing at the time. Conducting a trade study comparing cost, strength and environmental resistance of the current module and new materials, the team determined that acrylonitrile styrene acrylate, a thermoplastic polymer, is an optimal replacement material.
The team then carried out finite element analysis and topology studies to optimize material mass and mechanical strength. Finally, the team tested the new design and completed a feasibility study to determine whether the replacement is fiscally responsible. AMARG can use these results to inform their decision about which module design is better suited for their goals.
new design.
The team first explored the cost of materials, production and implementation of the current modules. One of the key findings was that the current wooden module was designed under the limitations of additive manufacturing at the time. Conducting a trade study comparing cost, strength and environmental resistance of the current module and new materials, the team determined that acrylonitrile styrene acrylate, a thermoplastic polymer, is an optimal replacement material.
The team then carried out finite element analysis and topology studies to optimize material mass and mechanical strength. Finally, the team tested the new design and completed a feasibility study to determine whether the replacement is fiscally responsible. AMARG can use these results to inform their decision about which module design is better suited for their goals.