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National Additive Manufacturing Innovation Institute

America Makes – National Additive Manufacturing Innovation Institute

Year in Review

NDIA Manufacturing Division Meeting 1/23/14

Ed Morris Vice President, National Center for Defense Manufacturing and Machining (NCDMM)

Director, America Makes – National Additive Manufacturing Innovation Institute

National Additive Manufacturing Innovation Institute

America Makes National 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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National Additive Manufacturing Innovation Institute

National Additive Manufacturing Innovation Institute

America Makes creates mechanisms for collaboration…

Pooling Resources / Pooling Risks

Public/Private Funded Projects Crowd 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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National Additive Manufacturing Innovation Institute

• 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

• $ 45M 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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National Additive Manufacturing Innovation Institute

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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

National Additive Manufacturing Innovation Institute

Director America Makes

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

Deputy Director: Advanced Manufacturing Enterprise • SME Coordination • Incubation/Commercialization • Supply chain and design modeling • Digital 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* “Champions” - Vision, Policy and Long-term Strategy and Planning

Governance Board** Technical strategy, program operating guidance

*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

= Direct Oversight /

Responsibility

= Guidance / Direction

Governance Structure – Shared Leadership

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National Additive Manufacturing Innovation Institute

DoD/NASA Benefits of Additive Manufacturing

Factory-less Production Remote, mobile fabrication

Agility / Flexibility Rapid response to changing missions

Shortening of Supply Chain Potential use of local raw materials

Additive Manufacturing could enable “focused logistics” – Right part, quickly, but only when needed

Local Production

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National Additive Manufacturing Innovation Institute

Membership Benefits

Community • Formalized community looking to leverage

AM Technologies

• Leverage learning curves

• Cooperatively solve similar issues

• Direct future equipment, material, and software development

• Technical strategy input

Work Force Development • Pre-K to grey training resources

• Immersive training/learning at America Makes facility

Projects • Lead America Makes directed project calls

• Team with America Makes & members to win additional government project calls

• Use America Makes resources for targeted company projects

Enterprise Data • Processing & Application data

• Material properties

• Supply chain

• Analysis

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National Additive Manufacturing Innovation Institute

86 Member Organizations (as of 1/22/14)

Lead Members listed in RED($200K) Full Members listed in BLUE ($50K)

Supporting Members in BLACK ($15K) * Original Members (39)

Stony Creek Labs Stratasys, Inc. Strategic Marketing Innovations, Inc. Stratonics* TechSolve* Texas A&M Univeristy The Timken Company* Tobyhanna Army Depot United Technologies Research Center University of Akron* University of California, Irvine University of Connecticut University of Louisville University of Maryland – College Park University of Pittsburgh* University of Texas – Austin University of Texas at El Paso University of Toledo USA Science and Engineering Festival Venture Plastics, Inc. Westmoreland County Community College* West Virginia University Wohlers Associates, Inc.* Wright State University Youngstown Business Incubator* Youngstown State University* Zimmer, Inc.

M-7 Technologies* MAGNET* Materion Corporation MAYA Design Inc. Michigan Technological University Missouri University of S&T MIT Lincoln Laboratory Moog, Inc. NE PA IRC* NorTech* North Carolina State University Northern Illinois Research Foundation Northrop Grumman* Ohio Aerospace Institute* Optomec* Oxford Performance Materials* Pennsylvania College of Technology Pennsylvania State University* PTC ALLIANCE Raytheon Company* Rhinestahl Corporation Robert C. Byrd Institute (RCBI)* Robert Morris University* RP+M RTI International Metals, Inc. * Sciaky, Inc. SME* Solid Concepts South Dakota School of Mines &

Technology

3D Systems Corporation* 3M Alcoa Allegheny Technologies Incorporated* Applied Systems and Technology Transfer (AST2)* Arkema, Inc. ASM International Association of Manufacturing Technology* Bayer Material Science* The Boeing Company Carnegie Mellon University* Case Western Reserve University* Catalyst Connection* Concurrent Technologies Corporation* Deformation Control Technology, Inc. DSM Functional Materials Energy Industries of Ohio* EWI The ExOne Company* General Electric Company (GE)* Hoeganaes Corporation Illinois Tool Works, Inc. Johnson Controls, Inc.* Kennametal* Kent Display* Lehigh University* The Lincoln Electric Company Lockheed Martin* Lorain County Community College

National Additive Manufacturing Innovation Institute

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

Lead $ 200,000 X X Full $ 50,000 X X

Supporting $ 15,000 X

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National Additive Manufacturing Innovation Institute

Entrusted Innovation Factory Equipment Equipment Manufacturer Model

Fused Deposition Modeling Stratasys Fortus 400MC

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

3D Systems Cube (2)

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

3DCAD Printer Hyrel

Plunge / "Dry" EDM Sodick (w/ POM Upgrades)

AQ55L

ROMER Laser Scanner Hexagon Metrology RASI-2

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National Additive Manufacturing Innovation Institute

Technology Roadmapping to Drive Investments

• Strategic Planning, Decision Making, and Collaboration Framework based on “Voice of the Customer”

• Near-, Mid-, & Long-term Investment Strategy

– Design

– Materials

– Process/Equipment

– Qualification/Certification

– Knowledge Development

• Structured Workshops Target Big Impact Outcomes

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National Additive Manufacturing Innovation Institute

Crowd-Sourced Roadmapping: RAPID Conference & Tech Strategy Workshops

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National Additive Manufacturing Innovation Institute

Technology Roadmap: Workshop Topics

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National Additive Manufacturing Innovation Institute

Technology Roadmap: v1.0

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National Additive Manufacturing Innovation Institute

Technology Roadmap: Continuous Improvement

Roadmap V1.0

Aerospace

Automotive

Medical

Energy

Electronics

Consumer

Technology Roadmap Advisory Group Being Formed 17

National Additive Manufacturing Innovation Institute

Project Call #1

• 7 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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National Additive Manufacturing Innovation Institute

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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National Additive Manufacturing Innovation Institute

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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National Additive Manufacturing Innovation Institute

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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National Additive Manufacturing Innovation Institute

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

•

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National Additive Manufacturing Innovation Institute

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

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

National Additive Manufacturing Innovation Institute

Digital Estate

• Replaced the NAMII Website with www.AmericaMakes.US

• New Look – New Capabilities to Serve the America Makes Community

• A Place to Grow & Connect the AM/3DP Community

Adaptive platform… Responsive to devices 24

National Additive Manufacturing Innovation Institute

Business Outreach Highlights

RAPID Conference & Expo

SFF Conference

Multiple Meetings with Prospective Members

“Breakthrough Competitive Advantage through Additive Manufacturing” – Co-hosted with

Council on Competitiveness & ORNL

Multiple Meetings with Current Members

Dr. Patrick Gallagher, NIST Director and Under Secretary of Commerce for Standards and Technology

State of Ohio Legislators Off-Site Meeting

Elana Broitman, Acting Deputy Assistant Secretary of Defense,

Manufacturing and Industrial Base Policy (MIBP) & Adele Ratcliff,

ManTech Director

Dr. Alex Slocum, Assistant Director, Advanced Manufacturing, Executive Office of the President

Office of Science and Technology Policy

Industry Week AM Webinar

GE AM Google+ hangout Webinar

Multiple Media Interviews

NSF Workshop on Frontiers of Additive Manufacturing Research

and Education

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National Additive Manufacturing Innovation Institute

Member & Community Outreach: Manufacturing Day Open House & Tours

• Over 1000 Visitors since April PMR for Business Meetings & Tours

• Business Meetings & Tours Have Grown from 16 per Month to 59 per Month

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National Additive Manufacturing Innovation Institute

2013 Education Summer Camps

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National Additive Manufacturing Innovation Institute

Introducing Additive Mfg to the FIRST Robotics Championship

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America Makes & ORNL Manufacturing Demonstration Facility (MDF) Joint Effort

National Additive Manufacturing Innovation Institute

Build A Disc Project Crowd Sourced Manufacturing Demonstration • 4/10/2013 – email to membership sent • 4/11/2013 – webpage to download disc

models • 17 Responding companies pledged 2000+

discs • 4/25/2013 – Final Results

– FDM, SLA, SLS Technologies represented – 2,373 discs inside of two weeks – 14 Companies contributed

Special thanks to America Makes

Members, you made this a success!

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National Additive Manufacturing Innovation Institute

Summary • Huge Opportunity with High Stakes

• “None of us can do it alone. For this to succeed, it needs to scale, and for it to scale, we need a passionate and motivated community” - Avi Reichental, President and CEO, 3D Systems

• “Rather than companies having to bear all of the cost and burden of qualifying these processes and materials, much can be done through collaborative efforts”

- Terry Wohlers, Principle Consultant and President, Wohlers Associates

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National Additive Manufacturing Innovation Institute