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Qualification and Certification at
America Makes – Coordinating the
Value Chain
John Wilczynski
America Makes
Deputy Director
Technology Development
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Why America Makes
The foundation is laid – in March 2012, President Obama proposed the
formation of a National Network for Manufacturing Innovation (NNMI) and
America Makes (National Additive Manufacturing Innovation Institute) was
launched in August as the initial Institute of Manufacturing Innovation (IMI).
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.
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Who We Are
America Makes is a public/private partnership
with substantial federal, private industry, and
academic investment.
The partnership is a multi-agency collaboration
between industry, government and universities,
led by the Defense-wide Manufacturing S&T team.
We have an innovation facility in Youngstown, Ohio.
We have 135 members and continue to grow.
We are operated by the National Center for
Defense Manufacturing & Machining (NCDMM)
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Why, How, What
AMERICA MAKES
WHY
The U.S. is not doing well in the Global Economy,
and needs a reinvigorated Manufacturing Sector
that includes a strong Defense Industrial Base.
HOW
Transform manufacturing in the U.S. through
innovative, coordinated Additive Manufacturing
Technology Development, Technology Transition,
and Workforce & Educational Outreach.
WHAT
Accelerated adoption of additive manufacturing
technologies in the U.S. manufacturing sector
that yield innovative products and increased
domestic manufacturing competitiveness.
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Collaborate
Cooperate
Innovate
AmericaMakes.us
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Why, How, What
TECHNOLOGY DEVELOPMENT
WHY
Society, technology, global competition are rapidly
changing. We must anticipate the change to keep pace.
HOW
Investing in and diversifying our manufacturing capability
portfolio (products and customers) through America Makes
membership collaboration that defines Additive
Manufacturing and 3D Printing:
Collaborate
Cooperate
Innovate
• Opportunity Requirements
• Product Deliverables
• Barriers to Entry
• Benefits to Membership and Government Partners
WHAT
Multiyear project calls aligned to America Makes roadmap
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Why, How, What
TECHNOLOGY TRANSITION
WHY
“Strive not to be a success, but rather to be of value.”
– Albert Einstein
HOW
• Deliver massive relevant value to the
America Makes membership
• Properly articulate the value delivered by
America Makes to all potential stakeholders
WHAT
Disseminate project results, maintain an robust Digital
Estate for members, leverage the membership and
additive manufacturing supply chain, establish America
Makes satellite centers of excellence, and accelerate
member commercialization of additive manufacturing
technologies.
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Collaborate
Cooperate
Innovate
AmericaMakes.us
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Why, How, What
WORKFORCE AND EDUCATIONAL OUTREACH
WHY
Additive Manufacturing is a game changing technology
that enables creative and competitive new designs,
products, markets, and educational opportunities.
Collaborate
Cooperate
Innovate
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HOW
Leverage America Makes member talents and
resources to define, develop and proliferate impactful
additive manufacturing educational initiatives.
WHAT
Prioritize and coordinate the development of
education/ training programs and resources to
accelerate Additive Manufacturing implementation.
AmericaMakes.us
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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
TRL & MRL
4–7
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How We Approach Innovation
Project Funding – We competitively award projects
to members using public and private funds, addressing prioritized
topics on our member-driven technology roadmap.
Our Vast Network – We act as a connector and facilitator
between all of our members. Everyone has a seat at the table
to contribute and collaborate with us and one another.
Workforce Readiness – Training and educational outreach
is a priority for the institute. Every Public/private funded
project requires an educational outreach component.
Technology Transition – We make it real. Every public/private
funded project requires a pilot transition component.
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Our approach to IP
CONSERVE  INTEGRATE  TRANSITION
You Own Your IP – You will own both
pre-existing IP and any you develop through
consortium effort.
All Consortium
Developed IP is owned
by the inventing
organizations–
We help to conserve,
integrate, and transition.
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We Provide Protection – We have a membership
agreement in place that is designed to protect your
interests by ensuring that all participants play by
the same set of rules.
Increase Chances of IP Adoption – We facilitate
IP transition through our project-based approach
and expansive network that represents multiple
industries, markets, and stakeholders.
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Technology Roadmap
Innovation projects are a member-driven, collaborative process
START
FINISH
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Types of Funded Projects
R&D INVESTMENT AREAS
Design
Material
Process
Value Chain Integration
AM Genome
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Types of Funded Projects
PROJECT MODELS:
Consortium-driven Project Calls
Agency-driven Projects
Member-drive Projects
Client-driven Projects
Competitively-awarded Projects
Crowd-sourced Projects
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Roadmap 2.0 – Level 1
resented at
2014Fall 2014
2015 PMR) 2016
2017
2018
Design
Material
Process
Value Chain
AM Genome
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Roadmap v2.0 Update – Level 2
Value Chain Level 2 Roadmap
2013
Maturation Needs
2014
2015
PC#3 Priority CTE Maturation Focus
“Gray Space” with < 5 CTE Maturation Ideas
2016
2017
2018
2019
PC#3 Priority
PC#3 Priority
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2020
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Non-Destructive Evaluation of Complex
Metallic Additive Manufactured Structures
PROBLEM
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Lack of NDE techniques for examination of
typical flaws in AM components
Only X-ray Computed Tomography (CT)
possible for complex geometries
OBJECTIVE
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Select aerospace components made of Ti64
and In718 with desired complexity
Conduct CT following AM fabrication process
Evaluate CT flaw detection and sizing
capabilities
Lead Organization: EWI
Supporting Organization(s): Rolls-Royce,
Lockheed Martin, GE Inspection Technol.
Start Date: 02/17/2015
End Date: 01/31/2017
APPROACH
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Two materials – Ti64 and In718
Two technologies – direct metal laser melting
(DMLM) and electron beam melting (EBM)
Flaws will be implanted in coupons and
components
Computer simulation to optimize experimental
matrix
Destructive testing to validate X-ray CT
capabilities
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BENEFITS
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IMPLEMENTATION
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Expand data about X-ray CT limits and
capabilities
Demonstrate model assisted approach to X-ray
CT technique verification
Substantiate industry standards and knowledge
Aerospace jet engine and frame
manufacturers, standard organizations (e.g.
ASTM), defense contractors, Air Force, NASA
Share results with industry during regular
reviews, meetings and publications in peer
reviewed journals
AmericaMakes.us
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A Proposed Open, Layered Protocol for Powder Bed
Additive Manufacturing
PROBLEM
•
No standard protocol currently exists
specifying the behavior of, monitoring, or
control of powder bed fusion additive
manufacturing (PBFAM) systems.
OBJECTIVE
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To develop and demonstrate an open, layered
protocol for PBFAM with commercial OEMs
and PBFAM system manufacturer.
Lead Organization:
Pennsylvania State
University Applied
Research Laboratory
Supporting
Organization(s):
3D Systems, Honeywell,
Northrop Grumman
Start Date: 02/10/2015
End Date: 08/09/2016
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Release
APPROACH
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Specify layered protocol based on existing
communication standards, where possible.
Define required software functionality.
Define neutral file formats.
Define necessary data transport and networks.
Define hardware requirements.
Demonstrate protocol on commercial 3D
Systems ProX-200 machine.
BENEFITS
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Researchers: Access to data for modeling,
sensing, control, and process optimization.
Industry: Ability to qualify, certify and innovate.
Machine Manufacturer: Increased customer
confidence and a development ecosystem.
IMPLEMENTATION
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Demonstrate on 3D Systems ProX-200 System.
Make protocol available to system manufacturers
and standards organizations.
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Development and Demonstration of Open-Source Protocols for
Powder Bed Fusion Additive Manufacturing (PBFAM)
PROBLEM
•
The lack of standard protocols for PBFAM has
hampered research efforts because users do not
have access to specific process parameter
information and toolpaths.
OBJECTIVE
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Develop & document open-source protocols for
PBFAM and demonstrate on commercial and
custom-made machines
APPROACH
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Define a LAYER protocol
Define a SCAN protocol
Demonstrate STL-to-LAYER conversion
Demonstrate LAYER-to-SCAN conversion
Demonstrate machined controller
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Make all of the above available to the opensource community for feedback and contributions
BENEFITS
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Lead Organization: GE Global Research
Supporting Organization(s): GE Additive
Development Center, Lawrence Livermore
National Lab
Start Date:
3/2015
End Date:
9/2016
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IMPLEMENTATION
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Improved control of PBFAM machines
A means to link process with modeling &
optimization efforts
GE GRC, GE Aviation and LLNL will implement
all software for demonstrations on commercial
and proprietary machines
Access to all results will be free to anyone
AmericaMakes.us
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Thermal Imaging for Process Monitoring and Control
of Additive Manufacturing
PROBLEM
Industry must have confidence in AM processes
where they can produce predictable microstructure
and distortion, both governed by thermal history
OBJECTIVE
Implement multi-sensor thermal imaging for process
monitoring and control on electron beam, wire-fed
(Sciaky’s electron beam direct manufacturing –
EBDM), and laser, powder-fed based (Optomec’s
Laser Engineered Net Shaping – LENS®) AM
processes.
• Performing Organization(s): PSU
• Start Date: May 2013
• End Date: February 2015
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APPROACH
• Integrate thermal sensors to adjust process real
time for increased quality/consistency of
microstructure and mechanical properties
• Harden sensors for EBDM process
• 3D visualization and correlation of data
• Expand process maps to real-time microstructure
control
BENEFITS
•Quality confidence in EBDM and LENS®
processes
•Multi-sensor thermal imaging and control installed
within Optomec LENS and Sciaky EBDM machines
• Increased adoption due to greater confidence in
part properties and quality
• Rapid qualification due to consistency in
microstructure and mechanical properties
IMPLEMENTATION
• Transition site in discussion
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Rapid Qualification Methods for Powder Bed Direct
Metal Additive Manufacturing Processes
PROBLEM
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Qualification of a process takes an exorbitant
amount of time, holding back adoption of
promising AM processes
Industry struggles to control microstructure and
mechanical properties across direct metal laser
sintering (DMLS) and electron beam melting
(EBM)
• Performing Organization(s): CWRU,
CMU, Pratt & Whitney, GE Aviation,
Lockheed Martin, Kennametal, Bayer, U.
Louisville, Wright State U, NC State
• Start Date: May 2013
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• End Date: February 2016
•
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APPROACH
Thermal property modeling, Power/Velocity
(P/V) process mapping to melt pool geometry
Determine effect of powder size distribution on
P/V process map and resulting microstructure
Construct process maps for DMLS and EBM
Develop process-based cost models
Demonstrate on “Industry Application”
BENEFITS
Verified methods for tight control of
microstructure and mechanical properties
Reduction in amount of testing/time to qualify
Ability to switch between high P/V (high rate,
low res) and low P/V (low rate, high res) will
provide overall faster build times and ability to
serve new markets
Industry uses cost models to make decisions on
adopting AM into their factory or supply chain
AmericaMakes.us
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NIST Measurement Science for AM (MSAM)
PROBLEM
• Advance innovation in measurement science for
Additive Manufacturing
• Performing Organization(s): Concurrent
Technologies Corp (CTC) / Edison Welding
Institute (EWI) / University of Louisville
(UofL)
• Start Date: September 2013
• End Date: October 2015
OBJECTIVE
• Develop in-process sensing and monitoring
capabilities
• Develop and validate non-destructive evaluation
techniques for post-manufacturing inspection
• Develop and refine “Layerwise Certification
Standard” for additive manufacturing
APPROACH
• Draw on the most advanced engineering schools
and most innovative manufacturers to collaborate
on new ideas, new technology, new methods, and
new processes
BENEFITS
• Ensure quality of Additive Manufactured
components are produced
• Certify Additive Manufacturing components for use
in end products
• Bridge the gap between commercialization and
federal investments
IMPLEMENTATION
• Diffuse measurement science for Additive
Manufacturing knowledge, expertise, and best
practices into the U.S. technology base
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When America Makes
America Works
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