Modeling machine promises precision Published Nov. 12, 2009 By Angela Cutrer Keesler News staff KEESLER AFB, Miss -- Members of the 81st Training Support Squadron Trainer Development Flight don't mind doing things the old-fashioned way. After all, they have a reputation for making exciting proposals come to authentic fruition. But that doesn't mean they don't embrace new technology such as the new modeling machine they recently obtained. The fused deposition modeling machine will enable production of more exact and faithful pieces for models for its training development needs. An initial idea by Keesler engineer Woody Wilson, the model-making machine has now been at the trainer development flight for about a month. "We're learning the programs and running models," said woodcrafter Greg Wilson. This new system employs "fused deposition modeling technology, the industry leading additive fabrication technology, and ... one that uses production grade thermoplastics to produce stable, durable and accurate parts," the company says. "Competitive processes only simulate thermoplastics using powders and resins. (Our) parts can be sanded, painted, drilled, coated, sealed and bolted" without any shrinkage, warping or moisture absorption. This means models at Keesler will go from a strategy to a reality more readily, and will be created to more faithfully represent what students will encounter in a "real-world" environment. "We'll be able to save time and create a neater job," Mr. Wilson said. "It can be more accurate and more functional. Engineers will be able to write a program on an file, save to a disc, and then we can load it into our computer that's hooked up to the FDM," Mr. Wilson said. The FDM can use different types of plastic materials for the modeling. For example, they will be able to use ABS, a form of plastic, and a PPSF medical grade plastic that can be sterilized for medical applications. This new process is better because they will be able to run production parts instead of using wood. "We can use this to produce parts within thousands of an inch," Mr. Wilson said. "Let's say someone wanted a model all the way down to its bolt. We'll be able to do that kind of precision." The new process is less expensive for the Air Force. Instead of using aircraft aluminum or some other high-dollar material that could cost thousands, the trainer development flight can make it for under $100. Plans are to have the FDM up and running by next summer. "Just be patient with us," Mr. Wilson said. "(The FDM) is new to us, but we're learning."