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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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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