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Leveraging Innovation in Advanced ManufacturingCarolina Innovations SeminarKirsten RiethApril 5, 2012
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Why care about innovation in manufacturing?
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U.S. manufacturing is important
Constitutes 11% of GDP Employs 12 million people Pays an average of $77,186 annually, including pay and benefits Employs 60% of engineers and scientists Performs two-thirds of all R&D in the nation, driving more innovation
than any other sector Accounts for ~30% of all energy consumption in the United States
Sources: Department of Energy Advanced Manufacturing Office, National Association of Manufacturers
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Industry needs innovation to remain competitive
~Joel Hans, Managing Editor, Manufacturing.net
“There’s little doubt that, at the very least, more manufacturers will be looking into open innovation in the next few years. The demand for faster product cycles will only get stronger, as will the need to make a product that’s both high quality and cheap. Even though open innovation is still in its infancy compared to many other business philosophies, it seems to have a great deal of potential, particularly in the way it connects disparate technologies for better solutions.”
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Manufacturing is a source of innovation, and co-location with design provides synergies for innovation
Advanced manufacturing provides high wage jobs
U.S.-based manufacturing is critical to national security
The U.S. government is focused on advanced manufacturing
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Advanced manufacturing is a family of activities that
(a) depend on the use and coordination of information, automation,
computation, software, sensing, and networking, and/or
(b) make use of cutting-edge materials and emerging capabilities
enabled by the physical and biological sciences, for example
nanotechnology, chemistry, and biology. This involves both new ways to manufacture existing products, and especially the manufacture of new products emerging from new advanced technologies.
Definition of advanced manufacturing
Source: Advanced Manufacturing National Program Office, National Institutes of Standards and Technology, U.S. Department of Commerce
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Revenue >$770M 13% average annual growth
over the last 10 years >2,800 employees in >40
countries >130 different academic
disciplines Independent and non-profit
RTI is an international R&D organization
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8
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University Collaborations
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Innovation Advising: Connecting Science and Business
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Manufacturing Example: Innovation Explored
Lehigh Valley Plastics is a plastics machining company
Problem
Plastic “stringers” on work centers
Air Products, Lehigh Valley, PA, Icefly cryogenic coolant system
Solution
Negative IMPACT• 1 shift/week lost to stoppages• Cooling fluid waste/handling• Machine and trip hazard
Positive IMPACT• 33% more capacity ($2.5M)• $20K/year less expense• Safety hazard elimination
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The U.S. government has many manufacturing programs• NIST Hollings Manufacturing Extension PartnershipDepartment of
Commerce• DARPA Disruptive Manufacturing Technologies Program• ManTech
Department of Defense
• Advanced Manufacturing OfficeDepartment of Energy
• Civil, Mechanical and Manufacturing Innovation Division National Science Foundation
• Right Skills NowSmall Business Administration
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Example program: NIST Manufacturing Extension Partnership
Source: www.nist.gov/mep
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New program: Advanced Manufacturing National Program Office
Source: Advanced Manufacturing National Program Office
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National Network for Manufacturing Innovation
Source: Department of Energy Advanced Manufacturing Office
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DoE suggested technologies for Manufacturing Demonstration Facility
•Aerospace, Automotive, Industrial applications, Desalination Low cost titanium (advanced low
cost/light weight metals)
•Chemical industry, buildings, oil and gas, water, wastewater treatment Advanced separations (membranes,
lower cost ionic liquids)
•Across nearly all advanced manufacturing industries In-Situ metrology and process controls
•Aerospace, Automotive Joining of disparate materials
•Chemicals, Metals, CHP, Transportation, Buildings Natural gas technologies
•Automotive, Wind Power, Industrial Motors Powder metallurgy processes (related to new magnets)
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Upcoming funding opportunities
National Network for Manufacturing
Innovation ($1B)
Pilot Institute for Manufacturing
Innovation (DoD, $45M)
Manufacturing Demonstration Facility (DoE)
Regional Innovation Economic
Development (EDA)
i6 Advanced Manufacturing
Jobs and Accelerator Challenge for
Advanced Manufacturing
Small Business Innovation
Research (SBIR)EPA: Innovation in
Manufacturing (closes May 3)
DoE: Advanced Manufacturing (pre-app
due May 1)
NSF: Nanotechnology, Advanced Materials, and
Manufacturing (due June 19)
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North Carolina and advanced manufacturing
Source: National Association of Manufacturers
Entrepreneurs
Industry
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LET’S TALK!
Questions?
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BACKUP SLIDES
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Energy Research Capabilities Process engineering Catalysis and sorbent
development Biomass and biofuels Advanced gasification Solar fuels Carbon capture technology Thermoelectric devices Solid-state lighting Photovoltaics Cement and concrete
Engineering and Technology
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Energy Research Technologies Syngas Desulfurization System
for Clean Coal Technology Dry Carbonate Process for
CO2 Capture from Flue Gas Reverse-Selective Polymer
Membranes for Hydrogen Production
Engineering and Technology
RTI InternationalEngineering and Technology
Advanced Materials Research Photonics Photovoltaics Flexible and organic electronics Cement and concrete Solid-state nucleonics Metamaterials Nanofibers Quantum dots
RTI InternationalEngineering and Technology
Advanced Materials Research Thermoelectric Technology
Solid State Heat Pump Thermoelectric Modules
(Nextreme) Thermoelectric Power
Generation Superlattice Thin-Film Materials DARPA DTEC Program
(Modules and Multi-Module Arrays from Superlattice Devices)
Cemex project CenSCI Center for Sustainable
Construction Infrastructure
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Electronics
Engineering and Technology
Advanced interconnection and packaging
Wafer and flip chip bumping and assembly
Die-to-chip and die-to-wafer bonding
3D integration Novel microfabrication and
passive device fabrication 3D through-silicon vias MEMS actuators and
transducers Sensors and integrated systems Thermal Electronic Hotspot
Cooling
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Electronics Micro Mass Spec pMUT Arrays and Device Vertical Interconnect Technology for
High Performance Infrared FPA Devices
SXM300 Embedded Computing Module (siXis)
Electrostatic Flexible Film MEMS Actuator
Nanoforce BioMolecular Sensor
Engineering and Technology
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Health and the Environment Biomedical engineering
Micro Mass Spec pMUT arrays and devices
Nanotoxicology Environmental monitoring Aerosol science Environmental
Asbestos Exposure
Engineering and Technology
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Health and the Environment Nanofiber Filters Nanofiber Performance Solid-state lighting Cement Industry Applications Biomass cookstove MicroPEM National Nanotoxicology
Materials Registry
Engineering and Technology
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Business Planning for Clean Energy Innovation Center
Project Impact
1. Requested and secured $24 million in funding
2. Enabled partnerships with industry and federal agencies, which will accelerate development and commercialization of energy technologies and the growth of a knowledge-based workforce
RTI developed an industry assessment and business plan for CAER, a regional Energy Innovation Center in Virginia that will support R&D and workforce development in the area of nuclear energy.
Example: Innovation Deployed
