SOW_Filament Extrusion_R13DN UPDATE 082123.docx

STATEMENT OF WORK

for Filament Extrusion System 8/20/2023

1. PURPOSE

Naval Surface Warfare Center Indian Head Division (NSWC IHD) Material Science Branch (R13) requires a filament extrusion system. This system must include an automatic filament extruder, a filament/plastic shredder, and accessory equipment required to produce high quality research filaments. This equipment will be used to make custom 3D printer filaments, with or without powder additives, for use in research experiments and to support advanced 3D printing development at IHD.

2. SCOPE

The contractor will provide a filament extrusion system which can process plastic feedstock of various sizes, with or without powder additives, into filament of high quality, automatically. The filament extrusion system will include a plastic shredder, plastic dryer, and a filament extruder.

The plastic shredder must be able to process bulk plastics of various sizes, up to 8in x 3in, into uniform granules that can be processed by the filament extruder. Bulk plastics, in this context, refer to solid pieces of plastic or failed 3D prints including 100% infill parts. Plastics of interest include ABS, PP, HDPE, LDPE, PETG, PLA, PEI, Nylon, and other 3D printer filaments. The shredder must be able to break down these materials into uniform granules below 10mm or to the required size for the filament extruder to ensure uniform extrusion.

The plastic dryer must be able to dry plastic granules produced by the plastic shredder in 1kg quantities. Drying times should be under 5 hours. The temperature of the dryer should be user selectable.

The filament extruder must be able to automatically maintain the required dimensional tolerances of 1.75 ±0.05mm or 2.85 ±0.05mm diameter filament. The filament extruder should be able to process materials up to 450°C. Research efforts require the addition of polymer additives or powders into the filament. The extruder must be equipped with inline mixing and cable of processing the additives uniformly into the filament.

A feeder must be provided to improve shredder if plastics.

Additional accessories should be provided where applicable. Such accessories include: spools for filament, additional nozzles for the extruder, plastics, and cleaning supplies.

3. REQUIREMENT

The contractor shall provide the following materials and components:

1. Plastic shredder – Quantity:2

a. Process bulk plastic parts (8in x 3in) down to <10mm particles

b. Particle separator

c. Integrated granulator to maintain uniform plastic granules

2. Plastic dryer – Quantity:1

a. Dry bulk plastic granules to remove moisture before extrusion

b. 1kg / 5 hours

c. Capacity for 1kg of plastic granules

3. Filament extruder – Quantity:2

a. Automated filament extrusion

b. Variable filament diameter for 1.75mm or 2.85mm filaments

c. High dimensional accuracy of ±0.05mm

d. Ability to incorporate powder/polymer additives with inline material mixing

e. Built-in filament spooler

f. Processing temperatures up to 450°C

g. Wired for 60Hz 110-120v power

4. Feeder for shredder – Quantity:1

a. Vibration powered device to improve plastic feeding into shredder

5. Accessories kit – Quantity:1

a. Any extras provided by the company to assist with filament production

4. PERIOD OF PERFORMANCE

Items must be purchased before the end of the FY (September 30th). Delivery of items to IHD must be completed as soon as possible.

5. TECHNICAL POINT OF CONTACT

NSWC Indian Head Division Material Science Branch (R13) Derek Neubert Indian Head, MD 20640 Phone: (301) 744-6646 Email: derek.d.neubert.civ@us.navy.mil