A novel application of rapid prototyping techniques to reduce production cost of geometrically complex supersonic missile inlets

This thesis documents the development and demonstration of a new, fully integrated design and fabrication technique for building geometrically complex objects to high accuracy without the expense of traditional machining. The technique described herein utilizes a unique combination of three-dimensional computer aided design (CAD), rapid prototyping techniques, conventional electroplating and computer numerically controlled final machining to fabricate usable prototype missile components for testing. The Single Master Model (SMM) technique was successfully demonstrated in the fabrication of complex three-dimensional supersonic inlets for a ramjet missile engine test program. The use of the SMM technique directly resulted in an order of magnitude reduction in fabrication costs (85%) when compared to conventional fabrication methods---without a significant loss in inlet performance. The development of the SMM approach is a major advancement in the area of usable component prototyping and frees the engineer and designer to approach design and fabrication with an accurate and relatively inexpensive new tool. The cost savings realized from the use of SMM are directly applicable to the manufacturing of other geometrically complex components.