America Makes National Additive Manufacturing …thor.inemi.org/webdownload/2014/National_Additive_Mfg_100914.pdf · National Additive Manufacturing Innovation Institute America Makes

National Additive Manufacturing Innovation Institute

America Makes – National Additive Manufacturing

Innovation Institute's Mission and R&D Portfolio

Ed MorrisVice President, National Center for Defense Manufacturing and Machining (NCDMM)Director, America Makes – National Additive Manufacturing Innovation Institutewww.AmericaMakes.US

2014 iNEMI Research Series

http://www.americamakes.us/


America MakesNational Additive Manufacturing Innovation Institute

• Conveys that additive manufacturing will change how America makes many things

• Communicates openness to all organizations – both traditional and non-traditional

• Changes the perception of manufacturing from a “dirty job” to a “cool profession”

• Reflects a strategy to innovate through collaboration and co-investment

• Emphasizes that we are an “accelerator” of technology development

• Represents a movement and a call to action

The National Accelerator for Additive Manufacturing & 3D Printing

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Projected AM Sales (products

and services)

“20% of output of 3D printers is now final products, rather than prototypes. By 2020 it may be 50%.” – The Economist (2011)

Why Additive?

A Manufacturing Revolution!$B

Government agency investments and interest - throughout NASA, DoD, and DOE Consumer Product

Market3


Benefits of Additive Manufacturing

Efficient use of ResourcesFewer processing steps, net-shape, less assembly, post-processing, less waste material, less energy

Small lot productions Production in lot size of 1, mass customization

Rapid manufacturing Tool-less, extreme cycle time reductions

Agile ManufacturingSpare parts on demand, no stockpiles, simplified

supply chain / logistics

Reverse Engineering Scan and manufacture parts for legacy systems

Cost Reduction Expendable / Disposable products

Lightweight Structures Weight removal increases mission capabilities

Modularity New Designs to switch components in and out

ComplexityExotic structures, Functionally-graded materials, fabricate moving joints, embedded electronics

Revolutionary Production

Enabling New Technology

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• Multi-agency collaboration between industry, government and universities, led by a Defense-wide Manufacturing S&T team

• Public-Private Partnership

• Shared facilities open to industry

― Especially attractive to entrepreneurs and small businesses

• Enabling technology transition and commercialization

• Addressing Technology Readiness Level (TRL) / Manufacturing Readiness Level

(MRL) 4-7

• Educational outreach and workforce development

• $50M gov’t investment pledged for pilot, $30M Cooperative Agreement awarded

A Model for Subsequent Manufacturing Innovation Institutes

What Is “America Makes – National Additive Manufacturing Innovation Institute?”

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America Makes creates mechanisms for collaboration…

Pooling Resources / Pooling Risks

Public/Private Funded ProjectsCrowd Funded Projects

Solving Problems

Collaboratively

Work Shops, Working Groups,Projects

Knowledge Base, Online Collaboration Tools, Databases, Specifications, Application Guides, Curriculum

Leveraging Community Knowledge

Cooperative Development of• Material Specs• Process Specs• Material Databases• Design Rules• Application Guides

Cooperative Development of• Training• Assessments• Case Studies

Why America Makes?

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http://www.google.com/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&docid=yjsi0NqObMNfpM&tbnid=1q50nwOI-sBaeM:&ved=0CAUQjRw&url=http://info.docuvantage.com/blog/bid/56835/Share-and-Collaborate-More-Efficiently-with-Online-Document-Management&ei=nJldUsqYKtSPkAeH2YDIDg&bvm=bv.53899372,d.eW0&psig=AFQjCNEgkaBy5vaFlV1wqPJsbh_Hq-kHgw&ust=1381952170918126

http://www.google.com/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&docid=yjsi0NqObMNfpM&tbnid=1q50nwOI-sBaeM:&ved=0CAUQjRw&url=http://info.docuvantage.com/blog/bid/56835/Share-and-Collaborate-More-Efficiently-with-Online-Document-Management&ei=nJldUsqYKtSPkAeH2YDIDg&bvm=bv.53899372,d.eW0&psig=AFQjCNEgkaBy5vaFlV1wqPJsbh_Hq-kHgw&ust=1381952170918126

http://www.google.com/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&docid=AkHVe2obH4GjoM&tbnid=5f1Ik3i3QLqUYM:&ved=0CAUQjRw&url=http://liveandlovelifeva.com/tag/online-collaboration-tool&ei=2ZldUs1WhOqQB5fugKAE&bvm=bv.53899372,d.eW0&psig=AFQjCNEgkaBy5vaFlV1wqPJsbh_Hq-kHgw&ust=1381952170918126

http://www.google.com/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&docid=AkHVe2obH4GjoM&tbnid=5f1Ik3i3QLqUYM:&ved=0CAUQjRw&url=http://liveandlovelifeva.com/tag/online-collaboration-tool&ei=2ZldUs1WhOqQB5fugKAE&bvm=bv.53899372,d.eW0&psig=AFQjCNEgkaBy5vaFlV1wqPJsbh_Hq-kHgw&ust=1381952170918126


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TRL/MRL 1-3 TRL/MRL 4-7 TRL/MRL 8-10

Universities

National Labs

Manufacturing Demonstration Facilities

Value Added Providers

Industry End Users


Deputy Director:Technology Development• Project Management• IP Management• Sustainability Thread

Deputy Director:Technology Transition• Outreach & Engagement• Technology Dissemination• Conferences & Events

Deputy Director:Workforce/Educational Outreach• Education Outreach• STEM activities• Workforce Training• Integrated Education thread

Technical Advisory Board***

OSD ManTech(Mfg and Ind. Base Policy)

Gov’t Co-op Agreement Program Manager (AFRL/RX)

*Executive Committee (11): Industry, for-profit organization (2), Non-profit

association (2), Academic (2), Government (3), At-large (2)

**Governance Board (35): Lead and Full Members, states ex-officio

***Technical Advisory Board (16): Army, Air Force, Navy, DLA, DARPA,

DOE, NASA, NSF, NIST, DoEd

= Direct Oversight /

Responsibility

= Guidance / Direction

Governance Structure – Shared Leadership

8

Operations Director America Makes

Governance Board**Technical strategy, program operating guidance

Executive Committee*“Champions” - Vision, Policy and Long-term Strategy and Planning

NCDMM VP & Director

America Makes


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Community Technology Tech Transition Enterprise Data Workforce Development

• Networking in a trusted environment

• “Co-opertition” – competitors collaborating

• Leverage learning curves

• Pool funding with others

• Access additional government funds for projects

• Lead and participate in applied research projects

• Technical strategy and policy input “Shape the Future”

• Access to the latest technology

• Technologyinvestments driven by industry “pull”

• Tools for finding partners both up and down the supply chain

• Access to all project results for commercialization

• Shared, trusted materials and processing data

• Supply chain analysis

• “Pre-K to gray” training resources

• Immersive training at Innovation Factory and member sites

“Additive manufacturing is our future.”

“We are proud to be members of America Makes”

“The degree to which competitors are collaborating is unprecedented.”

Membership Benefits


118 Member Organizations (as of 10/7/14)

Platinum Members ($200K) = RED; Gold Members ($50K) = BLUE; Silver Members ($15K) = BLACK ($15K); * Original Members (38)

Siemens Industry, Inc.SME*Solid ConceptsSouth Dakota School of Mines & TechnologySouthern Company Services, Inc.Stony Creek LabsStratasys, Inc.Strategic Marketing Innovations, Inc. Stratonics*TechSolve*Texas A&M University The Johns Hopkins University Applied Physics LaboratoryThe Timken Company*Tobyhanna Army Depot Tyco Electronics CorporationUL, LLCUnited Technologies Corporation University of Akron*University of California, Irvine University of ConnecticutUniversity of Dayton Research Institute University of Louisville University of Maryland – College Park University of Michigan Library University of Notre Dame University of Pittsburgh*University of Tennessee, KnoxvilleUniversity of Texas – AustinUniversity of Texas at El PasoUSA Science and Engineering Festival Venture Plastics, Inc. Westmoreland County Community College*West Virginia University Wohlers Associates, Inc.*Wolf Robotics Wright State UniversityYoungstown Business Incubator*Youngstown State University*Zimmer, Inc.

The Lincoln Electric Company Lockheed Martin*Lorain County Community CollegeLouisiana State University M-7 Technologies*MAGNET*Materials Sciences Corporation Materion CorporationMAYA Design Inc.MecklerMediaMet-L-FloMichigan Technological University Milwaukee School of Engineering Missouri University of S&TMIT Lincoln Laboratory Moog, Inc. NNSA's National Security CampusNorTech*North Carolina State UniversityNorthern Illinois Research FoundationNorthrop Grumman*Oak Ridge National Laboratory Ohio Aerospace Institute*OpenArcOptomec*Oxford Performance Materials*Pennsylvania State University*PTC ALLIANCERaytheon Company*Rhinestahl Corporation Robert C. Byrd Institute (RCBI)*Robert Morris University*Rolls-Royce Corporation RP+MRTI International Metals, Inc. *SABIC Innovative Plastics Business Sandia National Laboratories Sciaky, Inc. Senvol LLC

3D Systems Corporation*3MAdvance Methods in Innovation Alcoa Allegheny Technologies Incorporated*American Foundry SocietyApplied Optimization Inc. Applied Systems and Technology Transfer (AST2)*Arkema, Inc. ASM InternationalAssociation of Manufacturing Technology*Binghamton University Bayer Material Science* The Boeing Company Carnegie Mellon University*Case Western Reserve University*Catalyst Connection*Concurrent Technologies Corporation*Connecticut Center for Advanced Technology, Inc. DANTE Solutions, Inc.Deloitte Consulting, LLC DSM Functional Materials DVIRCEaton CorporationEWI The ExOne Company*General Electric Company (GE)*General Dynamics, Global Imaging TechnologiesGreenleaf CorporationGrid Logic IncorporatedHoeganaes Corporation Honeywell, Inc.Illinois Tool Works, Inc.Jabil Circuit, Inc. Johnson & Johnson Global Supply ChainJohnson Controls, Inc.*Kennametal*Lawrence Livermore National LaboratoryLehigh University*


Intellectual Property Strategy

• Membership Agreement outlines a comprehensive Intellectual Property Structure and Strategy

• All Consortium Developed IP is owned by the inventing organizations

• Rights to Consortium Developed IP are available only for IP developed during the time at which members are in good standing. This incentivizes early participation, and encourages long-term commitment.

• Project-level IP agreements are also completed, to include identification and protection of background IP

• Use of Consortium Developed IP is as follows (tiered structure):

America Makes Membership

Level

Annual Fee(cash or cost

share)

Free Access to Consortium

Developed IP for R&D

Use of Consortium Developed IP for

Commercialization

Royalty-free Use of Consortium Developed

IP for Commercialization

Platinum $ 200,000 X XGold $ 50,000 X X

Silver $ 15,000 X

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Entrusted Innovation Factory EquipmentEquipment Manufacturer Model

Fused Deposition Modeling StratasysFortus400MC

Selective Laser Melting Renishaw AM 250Bonded Plaster Z-Corp Z-Printer 310Selective Laser Sintering 3D Systems SLS sPro 60Wax Depositon 3D Systems ThermojetBonded Refractory Material ExOne M-LabMaterial Extrusion (3D Printer)

3D Systems Cube (2)

Direct Metal Deposition POM Synergy 5Material Extrusion (3D Printer)

3DCAD Printer Hyrel

Plunge / "Dry" EDMSodick (w/ POM Upgrades)

AQ55L

ROMER Laser Scanner Hexagon Metrology RASI-2

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Entrusted Innovation Factory SoftwareApplication ManufacturerGeomagic Control 2014 3D SystemsGeomagic Studio 2014 3D SystemsGeomagic Wrap 2014 3D SystemsBuild Station 3D SystemsCubify Invent 3D SystemsCube X 3D SystemsAutoFab64 MARCAMSpaceClaim 2012+ SpaceClaimInsight 9.1 StratasysControl Center 9.1 StratasysSimplify3DProMetal R-1SolidWorks 2014RDS 3.6

Simplify3DExOneDassault SystemesHexagon Metrology

Product Lifecycle Management including Teamcenter and NX

Siemens

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Technical Investment Strategy

• “Voice of the Customer” drives strategic investment plan

• Crowd-sourced consolidated technical roadmapping

• Project Calls address gaps/needs of greatest impact to industry

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Need/Issue Impact if not Addressed

Dimensional accuracy & surface finish Additional processing cost, unusable parts

Uniform mechanical properties – different in build direction

Increased design complexity & added weight, suboptimal designs

Improved process control & repeatability Acceptable part quality, process yield & cost

NDE methods for complex defects and part geometry-understanding of potential defects – effects of defects

Undetected defects leading to component failure.

AM Standards (Materials, process,machine, quality)

Slow implementation of AM in industrial base

Qualification and Certification protocols Slow adoption, conflicting approaches, waste in research and sustainment dollars

Design tools for AM components Suboptimal design, increased time to market, material waste, poor performance

Capability Gaps/Issues


Multiple Investment Options to Attract Different Stakeholders

Project Models:• Consortium-driven Project Calls

– Industry-driven roadmap developed highlighting capability gaps

• Agency-driven Projects

– AF: Laser Powder-feed Special Topic Call ($2.9M)

– More coming….

• Member-driven Projects

– First one using all private investing in tech detail planning phase

• Client-driven Projects

• Competitively-awarded Projects

– NIST: Measurement Science ($5M)16


Technology Roadmap: v1.0

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Project Call #1

• 6 Projects Awarded; April 2013 Kick-off

• Projects Address Metals & Polymers

– Materials Characterization

– Process Capability & Characterization

– Quality Control

• $9.5 M Technical Investment ($4.5M Government Funds + $5M Cost Share)

• Each Project includes Technology Transition, Advanced Manufacturing Enterprise, and Workforce Education

• 35 Participants (8 of the 35 Are Universities)

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Project Call #2

• Eight Priority Topics Selected Based on Crowd-Sourced Roadmapping Process

• Solicitation Issued 8/29/13; Proposals Received 10/31/13

• Announced 15 Project Awards 1/21/14

• Awarding $9M of America Makes Funding with $10.3 million matching cost share from awarded project teams = $19.3M total funding

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Project Call #2 Topics• Design for Additive Manufacturing

– Complex and Reproducible Designs via Modeling and Simulation Tools

• Additive Manufacturing Materials

– Sustainable Materials for AM / 3DP

– Gradient and Tailored Materials

• Process and Equipment

– Next Generation Machine

– Multiple Materials Processing Equipment

– Energy Self-Monitoring Additive Manufacturing Equipment Systems

• Qualification and Certification

– Non-Destructive Evaluation of Complex Geometries

• Knowledgebase Development

– Process / Properties Validation Data Set

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Project Call #2 Awards• “In-Process Quality Assurance (IPQA) for Laser Powder Bed Production of

Aerospace Components” - General Electric Aviation

• “Developing Topology Optimization Tools that Enable Efficient Design of AM Cellular Structures” - University of Pittsburgh

• “AM of Biomedical Devices from Bioresorbable Metallic Alloys for Medical Applications” - McGowan Institute for Regenerative Medicine at the University of Pittsburgh

• “Refining Microstructure of AM Materials to Improve Non-Destructive Inspection (NDI)” – EWI

• “Development of Distortion Prediction and Compensation Methods for Metal Powder-Bed AM” - GE Global Research

• “Development of a Low-Cost ‘Lens® Engine’” - Optomec

• “Development of Knowledgebase of Deposition Parameters for Ti-6Al-4V and IN718”- Optomec

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Project Call #2 Awards (Cont’d)• “Automatic Finishing of Metal AM Parts to Achieve Required Tolerances &

Surface Finishes” - North Carolina State University

• “Electron Beam Melted Ti-6Al-4V AM Demonstration and Allowables Development” - Northrop Grumman Corporation

• “3D Printing Multi-Functionality: AM for Aerospace Applications” -University of Texas – El Paso

• “Metal Alloys and Novel Ultra-Low-Cost 3D Weld Printing Platform for Rapid Prototyping and Production” - Michigan Technological University

• “Accelerated Adoption of AM Technology in the American Foundry Industry” - Youngstown Business Incubator (YBI)

• “A Database Relating Powder Properties to Process Outcomes for Direct Metal AM” - Carnegie Mellon University

• “High-Throughput Functional Material Deposition Using a Laser Hot Wire Process” - Case Western Reserve University

• “Optimization of Parallel Consolidation Method for Industrial Additive Manufacturing” - - Stony Creek Labs 22


NIST MSAM Cooperative Agreement Program Award

• Won $5M, 24-Month NIST Measurement Science for Advanced Manufacturing (MSAM) Cooperative Agreement Program: “Holistic Approach to Solving Measurement Science Challenges in Additive Manufacturing”

– Informative In-Situ Process Monitoring

– Non-Destructive Evaluation

– Layerwise Quality Certification for Additive Manufacturing

• NIST Also Awarded $2.4M Program to Northern Illinois University (an America Makes Member) to develop tools for process control and qualifying parts made with layer-by-layer additive-manufacturing processes

23Quality Parts Produced and Certified for Use in End Product(s)


Business Outreach Highlights

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Defense Manufacturing Conference Multiple Meetings with Prospective Members

ASTM F-42 Committee Memorandum of Understanding

Multiple Meetings with Current Members• Lockheed Martin Corporate Production Council• Northrop Grumman Additive Manufacturing Consortium

U.S. Senate Commerce Committee Staffers

MMPDS Leadership

U.S. House of Representatives Subcommittee on Research & Technology, Committee on Science,

Space and Technology Staffers

OAI 4th Annual Industry Forum

ASME Senior LeadershipMultiple Media Interviews

Whitehouse “We The Geeks”

Google Hangout

South Carolina Chamber of Commerce

AERODEF 2014

TEDx Youngstown

Coordinate, Cooperate, Innovate!


Educational Outreach• Strong emphasis on STEM for K-12

• Partnering and leveraging many existing programs– FIRST Robotics, AST2 Community Outreach

Exhibit, ASM Teachers Camps, 3D Printing Summer Camps

• “3D Printers in Every School”

– Audacious STEM goal

– 100% private funding

– ~500 3D printers funded (4 wks)

– Training, support, and materials

– Expecting many desktop printer manufacturers to join initiative

www.makerbot.com/academy 25

“2014 First Robotics Best Use of 3DP”Hardin Valley Academy, Oak Ridge, TN

Awarded 3D Systems Cube

3DP Hospital Repair at 2014 First Robotics

Championship

http://www.makerbot.com/academy


Education Summer Camps

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Summary

• We’ve moved beyond “Start-up”

• Building on what we’ve learned is still a learning process – it’s ingrained in being innovative

• Keeping our Strategic Investment Plan Roadmap Current is crucial – the landscape is fast moving and evolving

• “Huge Opportunity with High Stakes” is an understatement!

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“Even if you're on the right track, you'll get

run over if you just sit there.” - Will Rogers


America Makes National Additive Manufacturing …thor.inemi.org/webdownload/2014/National_Additive_Mfg_100914.pdf · National Additive Manufacturing Innovation Institute America Makes

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