The NationalAdditive Manufacturing Innovation Institute

Transcription

1 Driven by America Makes The NationalAdditive Manufacturing Innovation Institute Smart Collaboration Leveraging a rich knowledge base to gain competitive advantage in the additive manufacturing industry: Trends and OVverview Rob Gorham America Makes Executive Director

2 Trend: Automotive Worlds First Drivable 3D Printed Car

3 Trend: Pharmaceutical Worlds First FDA-Approved 3D Printed Drug

4 Trend: Space Worlds First Student-Designed 3D Printed Tool in Space

5 Trend: Aerospace Worlds First FAA-Approved 3D Printed Part for the Dreamliner

6 National Center for Defense Manufacturing and Machining (NCDMM) Delivering Manufacturing Innovation Established in 2003 Non-profit Manufacturing Solution Provider Independent, Unbiased Project-Based (multiple contractual mechanisms) Focus on Improved Cost, Quality, Performance Rapid Deployment to Industry and the Warfighter America Makes Administrator Collaborate with government, industry, and academia to promote best practices, and deliver them to key stakeholders we connect the dots

7 Why Manufacturing USA, Why America Makes The foundation is laid In March 2012, the formation of Manufacturing USA was proposed and America Makes, the National Additive Manufacturing Innovation Institute was launched in August as the initial Institute of Manufacturing Innovation. The vision is simple Leverage our nation s brilliant technical minds in all corners of government, industry and academia to accelerate the adoption of additive manufacturing technologies in the U.S. manufacturing sector and increase domestic manufacturing competitiveness. The goal is bold Create truly collaborative environments to bring technology advancements from the lab to the factory floor, create jobs, produce more competitive products, and ultimately reaffirm our place in the global market.

8 Who We Are Public / Private Partnership America Makes has substantial federal, private industry, and academic investment. Multi-Agency Collaboration Partnership between industry, government and universities, led by the Defense-wide Manufacturing S&T team. Membership Innovation facility in Youngstown, Ohio with over 180 members. We continue to grow. Operations We are operated by the National Center for Defense Manufacturing & Machining (NCDMM)

9 Key Takeaways How We Fit America Makes has established itself as a impartial convener of AM industry stakeholders, a coordinator of technical and workforce data, and the activation catalyst through high value / high difficulty / high impact collaborative projects. America Makes, through enabling access to roadmap aligned, coordinated data, is transforming Additive Manufacturing stakeholder investment priorities. Information to insight. This is a critical aspect of the Department of Defense Better Buying Power 3.0. America Makes systems engineering based roadmap methodology and intent is a unique and rigorous process that serves as the common language for aligning and linking any AM initiative (public or private) to the common America Makes roadmap framework. America Makes has developed a full spectrum approach to AM capability growth focusing on mission, governance, insights, talent, complimentary technologies, and processes.

10 America Makes Quick Facts Additive Manufacturing Roadmap (Technology and Workforce) Released Additive Manufacturing Roadmap for Department of Defense Released Additive Manufacturing Standards and Specifications Roadmap Released 181 Members, 90% retention and 25% annual growth 66 projects (with over 80 members participating and cost share ratio of 1.1), $97M awarded with $86M pending Over 30,000 online collaborators via the America Makes Digital Estate

11 Focus: Robust, Sustainable Value Chain Widespread adoption of AM depends on organizations developing AM capabilities, not just purchasing machines (see link)

12 Our Purpose Our main goal is to Bridge the Gap and address Technology & Manufacturing Readiness Levels (TRL & MRL) 4-7 enabling technology transition and commercialization through funding innovation projects. Government & Universities Private Sector Invention TRL & MRL 4 7 Commercialization

13 AM Opportunities and Challenges Opportunities Challenges Unprecedented design flexibility, allowing customization and new product development Consumerization / personalization of manufacturing Novel end-market applications in areas such as regenerative medicine Relocalization of US manufacturing Rapid product development and deployment Improving process sustainability (fewer yet greener materials; less energy and waste associated with production) Exuberance vs natural evolution and true potential of the technology Ethical considerations Intellectual property / privacy issues Regulatory uncertainty in different countries Limited choice of materials Limited design tool capability Materials and process manufacturing qualification and certification standards Small production runs and scalability limitations

14 Technical Capability / Gaps Issues Overview Need/Issue Dimensional accuracy & surface finish Uniform mechanical properties different in build direction Improved process control & repeatability NDE methods for complex defects and part geometry-understanding of potential defects effects of defects AM Standards (Materials, process, machine, quality) Qualification and Certification protocols Design tools for AM components Impact if not Addressed Additional processing cost, unusable parts Increased design complexity & added weight, suboptimal designs Acceptable part quality, process yield & cost Undetected defects leading to component failure. Slow implementation of AM in industrial base Slow adoption, conflicting approaches, waste in research and sustainment dollars Suboptimal design, increased time to market, material waste, poor performance

15 Swimlane Critical Technology Element Impact Focus Design Material Process Value Chain AM Genome Bio-Inspired Design & Manufacturing Cost & Energy Driver Driver Analysiss Design Aides/Apps Additive Mfg Tech Data Packages Next-Gen Materials Powder/Material Characterization Multi-Material Delivery & Deposition Next-Gen Machines Process Temperature Gradient Control Digital Thread Integration Advanced Sensing & Detection Methods Intelligent Machine Control Methods Rapid Inspection (Post Build) Repair Technologies Standards/Schemas/Protocols Benchmark Validation Use Cases Physics-Based Modeling & Simulation Model-Assisted Property Prediction Complexity Exploitation, 3D Graded Materials, Multi- Material Integration, Model-Based Development, Product Customization Standard Feedstock Materials, Benchmark Property Data, Microstructure Relationships, Process Window Definition, Processing Guidelines & Specifications Faster Build Speeds, Improved Surface Quality, Larger Part Envelopes, Improved Detail Capability Material Costs, Processing Costs, Quality Control Costs, Productivity Costs, Energy Efficiency Costs Concurrent Methods, Computational Tools, Experimental Tools, Modular Open Simulations, Open Multi-Scale Data

16 America Makes Roadmapping for DoD Major Section of the DoD AM Roadmap

17 America Makes Roadmapping Cross-Cutting Technology Enablers for AM

18 Data Management at America Makes The America Makes Digital Storefront Objectives: Improve buying decisions across the institute stakeholders (operations, investment, R&D, capital expenditure, research area) Improve public and member access to, search and discovery of, and consumption of AM intellectual capital assets Extend and improve traceability of intellectual capital both depth of traceability throughout intellectual capital hierarchy and consistency of traceability between intellectual capital Improve reporting and analytics Advance toward establishment of single source of data (truth) for each intellectual capital type; both internal assets and links to relevant external sources Status: Implementation completed in December 2016 Rolled out to America Makes stakeholders the week of March 13, 2017 Phase 3 (Data Analytics) scoped but not budgeted Bull t Das Sub-

19 in partnership with 19

20 Digital Storefront Architecture Summary

21 Workforce and Education What We Have Learned EDUCATION RECOMMENDATIONS Promote K-12 Education STEAM programs across formal and informal environments Ensure AM Curriculum provides students with understanding of processes, material properties and Design for AM Recommendation to develop a national network for AM Education Provide support for collaborative and community-oriented maker spaces Develop Opportunities for Trans-Disciplinary Learning WORKFORCE CHALLENGES Insufficient skills for using current design/analytical tools Lack of training for equipment use/maintenance Lack of design for additive manufacturing awareness Lack of general understanding of use-cases for additive manufacturing Lack of understanding of commercial and economic considerations Lack of credible industry-wide source for hands-on training, resulting in reliance on webinars

22 Workforce and Education Summary Key Initiatives Align to Roadmap Focus on AM Impact and Scale KEY INITIATIVES PROJECT CALL 4 7 New WEO Projects Funded Align to WEO Roadmap Innovation Factory Advanced Curriculum in Additive Design, Engineering and Manufacturing Innovation ACADEMI WEO ROADMAP V2 Investment Strategy Roadmap Provides the Big Picture Prioritizes Major Initiatives and Investments as a Living Document

23 Workforce and Education Roadmap Level 1

24 WEO Roadmap Project Recommendations

25 Example: Success Story Additive Manufacturing for Metal Casting AM4MC ( ) Problem / Need There are two key barriers to the adoption of AM Sand Printing in the industry of metal casting production operations: 1. Cost both capital (machines and operations) and consumables (material) 2. Slow process speeds Objectives Improve AM application for full production of castings in Three (3) areas of opportunity: Demonstration of fast printing technology hardware that is affordable to SMEs Reduce operational cost and support regional manufacturing system integration Reduce the volume of sand required to minimize production time and cost

26 Approach Focus on the design of fast printing technology hardware Hardware designed must work with open-source bonding resins and aggregates to reduce operational cost Design and develop flexible print settings to optimize and reduce the volume of sand required to minimize production time and cost Develop, Demonstrate, and Transition of 3D Sand Printing technology by focusing on : Next-Gen Machine (Process CTE) Design Rule (Design CTE) Project to be augmented by LIFT investments in metallurgy and inorganic binder system development for thin walled castings. Transition TRL from 4 to 7 and MRL from 3 to 7. Key Technologies Metal casting AM Sand Printing Inorganic binder systems Design software Impact Mass manufactured vehicle optimization would benefit from AM Sand Printing Improved fuel economy Lower emissions to environment

27 Prime Contract (thru AFRL): Rob Gorham PM NCDMM / America Makes Subcontractor/Lead Organization: Youngstown Business Incubator Rich Lonardo Principal Investigator (PI) Project Team Organizations: Youngstown State University (YSU) University of Northern Iowa (UNI) Penn State University (PSU) American Foundry Society Ford Tinker Omega Manufacturing, LLC Humtown Products Dassault Systems

28 Additive Manufacturing for Metal Casting AM4MC ( ) PROBLEM/NEED Cost (both capital and consumables) and Slow Process Speeds are two key barriers to the adoption of AM Sand Printing in the industry of metal casting production operations. OBJECTIVE Three focus areas to improve AM application for full production of castings: Demonstration of fast printing technology hardware that is affordable Reduce operational cost and support regional manufacturing system integration Reduce the volume of sand required to minimize production time and cost APPROACH Focus on design of fast printing technology hardware Hardware designed to work with open-source bonding resins and aggregates to reduce operational cost Design and develop flexible print settings to optimize and reduce the volume of sand required to minimize production time and cost BUSINESS STRATEGY Program: America Makes Stakeholder: Various Performing Organization(s): NCDMM / Youngtown Business Incubator (YBI) / Youngstown State University (YSU) / University of Northern Iowa (UNI) / Penn State University (PSU) / Ford / America Foundry Society / Tinker Omega Manufacturing LLC / Humtown Products / Dassault Systems Start Date: Aug 18 th, 2016 (Official Kick-Off meeting was in early Dec, 2016 at Ford with pre-kickoff held Oct to Dec getting subs on) End Date: Feb 25 th, 2018 Funding ($) Federal $ $ 999,000 Cost Share $ 1,045,000 LEVERAGED EFFORTS Project to be augmented by LIFT investments in metallurgy and inorganic binder system development for thin walled castings BENEFITS Mass manufactured vehicle optimization efforts, including fuel economy and lower emissions would benefit from AM Sand Printing IMPLEMENTATION Next generation Sand Printing equipment developed and commercialized by Tinker Omega Manufacturing LLC Design software commercialized by partnership of UNI, YSU, PSU, and YBI WEO efforts to include Instructor Led Labs (Hands-on Learning CTE) E-learning Courses (Knowledge & Awareness CTE) Customized Training (Trainee Programs CTE)

29 Future Trend: Multi-Material 3D Printing

30 Future Trend: Organic 3D Printing

31 Future Trend: Metal Metal Metal

32 Future Trend: Generative Design

33 Future Trends: Other Leverage the world Certifications / Workforce Hybrids

34 When America Makes America Works /AmericaMakes