april 9, 2019 - better buildings initiative · 2019-05-31 · large optics diamond turning machine...
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LLNL-PRES-771652This work was performed under the auspices of the U.S. Department of Energy by Lawrence Livermore National Laboratory under contract DE-AC52-07NA27344. Lawrence Livermore National Security, LLC
April 9, 2019
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Lawrence Livermore National Laboratory LLNL-PRES-7716522
Manufacturing Team - 1961
Electronics cable shop - 1960
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Lawrence Livermore National Laboratory LLNL-PRES-7716523
Water Jet is added to LLNL Manufacturing’s capabilities providing significant time savings over traditional saw cutting or rough machining (1990)
Laser cutting, welding and drilling provide a new manufacturing technology (late 1970’s)
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Lawrence Livermore National Laboratory LLNL-PRES-7716524
Machinist prepares to rework a NOVA Beam Tube on the Gilbert Horizontal Boring Mill in the B321 Main Bay. (2002).
Approx. 42” dia. X 26’ long & 9,300 lbs
Machining the TARPOS seal surface to enable assembly (2003)
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Lawrence Livermore National Laboratory LLNL-PRES-7716525
1960 - 1980 2000 2010
Diamond-turning machinesDTM-1, DTM-2, DTM-3, LODTM, PERL
Weapon componentsOptical components
Carbon-fiber composites
MicrofabricationSensors, bio systems, electrical/optical devices
1990
Precision engineeringFabrication, assembly, metrologyError budgetingDesign for manufacture
NASA mirrors
KDP finishing
LCLS x-ray phase lens
NIF ignition target
2-meter telescope mirror
EUVL camera
Diamond anvil pressure sensor Retinal prosthesis
Hydrogen fuel tank Electrostatic flywheel
Additive manufacturing
Biobriefcase
2020Munitions
Commercial diamond turning
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Lawrence Livermore National Laboratory LLNL-PRES-7716526
Fabricationdiamond-turning of
2-meter mirror
AssemblyNIF ignition target
height ~1 cm
MetrologyDimensional inspection
of conical opticdiameter = 250 mm
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Lawrence Livermore National Laboratory LLNL-PRES-7716527
Large Optics Diamond Turning Machine (LODTM) - World’s most accurate lathe- Calibrated accuracy of <0.1-µm over 1.5-m dia.- Numerically-controlled diamond tool- Originally designed to manufacture optics
for space-based system- Used for large, aspherical mirrors
1984 – 2009
Precitech 5-axis Diamond Turning Machine - Installed 2018- Freeform precision turning and milling- Turning surface finish <1.5 nm- Used for fabrication of NIF targets
Current
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Lawrence Livermore National Laboratory LLNL-PRES-7716528
Double-Shell Ignition Targets
Fabrication: Diamond turning of aerogel + inner capsule
Assembly: Hohlraumwith inner assembly
Characterization: X-ray CT slice of gap
Gap for cryogenic geometry
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Lawrence Livermore National Laboratory LLNL-PRES-7716529
An Open User facility for all Laboratory employees and outside partners
Certified Class 100 Cleanroom, Class 10 areas
Broad Semiconductor device capabilities
Dedicated medical device foundry
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Lawrence Livermore National Laboratory LLNL-PRES-77165210
Pillar thermal neutron detector array
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Lawrence Livermore National Laboratory LLNL-PRES-77165211
• Design, fabrication, packaging, integration and characterization of micro- and nanosystems for biologic applications
• Long-term implantable biomedical devices
• Electrode material development and characterization
• 3-D fabrication & 3-D bioprinting technologies
NIH - Brain Research Through Advancing Innovative Neural technologies (BRAIN) Initiative
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Lawrence Livermore National Laboratory LLNL-PRES-77165212
Implantable Devices to cure neurological disorders:
• Depression• PTSD• Parkinson's
Artificial Retina R&D 100 & Editors Choice 2009
Neural ImplantsElectrically stimulate or record neurons and deliver or measure chemical agents
Flexible polymer electrode device to stimulate the optical
nerve with image data
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Lawrence Livermore National Laboratory LLNL-PRES-77165213
Improved performance of fiber composites addresses difficult national security needs
DOD Asymmetric warfare Energy storage and generation Aircraft and Space
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Lawrence Livermore National Laboratory LLNL-PRES-77165214
DesignSimulation
Optimization
SynthesisFabricationAssembly
MetrologyCharacterization
TestingSimulation
Wind pattern
Mechanical testing
Digital image correlation X-ray CT imaging
Multiscale
CNC Filament windingCustom layup
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Lawrence Livermore National Laboratory LLNL-PRES-77165215
Manufacturing capability includes:• 2 CNC filament winders• 1 large CNC lathe/mill turning
machine• Multiple ovens to cure various
sizes of composite parts
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Lawrence Livermore National Laboratory LLNL-PRES-77165216
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Lawrence Livermore National Laboratory LLNL-PRES-77165217
Model Image correlation
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Lawrence Livermore National Laboratory LLNL-PRES-77165218
Computational Engineering
Structural analysisModel orthotropic material response
Simulate composites under dynamic
conditionsMultiscale modeling
Model processing and parameters
Synthesis and Fabrication
Materials development(hybrid fiber, etc.)
Multicomponent material systems
Filament winding thermal processingMachining
Coupling to metal components
Assembly
Characterization and testing
Microstructurecharacterization
RheologyNondestructive
evaluationMechanical testing
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