Quality Metal Additive Manufacturing (QUALITY MADE) - PowerPoint Presentation

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Quality Metal Additive Manufacturing (QUALITY MADE)

Call for Teaming

Rob Gorham

America Makes

Director of Operations

Call for Teaming

Logistics

NCDMM Intends to Prime a Response to the Broad Agency Announcement (BAA)

NCDMM BAA Response to Integrate America Makes as Core

Capture Manager: Rob Gorham

ACTION: Teaming Interest due to

rob.gorham@ncdmm.org

by September 11 (see last slide)

ONR Information

BAA Announcement Expected October 2015

Program Start Expected October 2016

Duration: 4 Years, FY17-20

Why America Makes

Win Strategies

Leverage the America Makes Mission (Process, Org, Network)

Leverage Current Funded Projects Driven Aligned to the America Makes Membership Led Roadmap v2.0

Leverage the Growing Membership Strength and Diversity

Leverage the Intellectual Property Model for Transition

QUALITY MADE Program Goals

QUALITY MADE Program Goals

QUALITY MADE Program Goals

Roadmap

v2.0 Update – Level 1

resented at Fall 2014 PMR)

2014

2015

2016

2017

2018

Process

Material

AM Genome

Value Chain

Standards/Schemas/Protocols (10 Ideas)

Design

Repair Technologies (1 Idea)

Advanced Sensing and Detection Methods (5 Ideas)

Intelligent Machine Control Methods (4 Ideas)

Digital Thread Integration (4 Ideas)

Rapid Inspection Technologies (1 Idea)

Multi-Material Delivery & Deposition Systems (3 Ideas)

Next-Gen Machines (8 Ideas)

Process Temp Gradient Control (2 Ideas)

Material Property Characterization (10 Ideas)

Next-Gen Materials (6 Ideas)

“Non Ad-Hoc” Additive Manufacturing Tech Data Packages (7 Ideas)

Product & Process Design Aides/Apps (12 Ideas)

Cost & Energy Driver Analysis/Modeling (5 Ideas)

Bio-Inspired Design & Manufacturing (2 Ideas)

Model Assisted Property Prediction (2 Idea)

Benchmark Validation Use Cases (3 Ideas)

Physics-Based Modeling & Simulation (5 Ideas)

2013

2014

2015

2016

2017

Design Level 2 Roadmap

Maturation Needs

Ti-64 DMLS Production Cost Modeling (4009.001)

Cost & Energy Driver Analysis/Modeling (5 Ideas)

Bio-Inspired Design & Manufacturing (2 Ideas)

Roadmap v2.0 Update – Level 2

Ti-64 EBM Production Cost Modeling (4009.001)

Cradle-to-Cradle Life Cycle Energy Use Modeling (v1.0)

Product/Process Family Energy Use Modeling (v1.0)

Product & Process Design Aides/Apps (14 Ideas)

Cellular FEA Topology Models for DMLS Ti-64 (4021.001)

Efficient Structural Analysis Algorithms for Cellular Structures (v1.0)

FDM ULTEM 9085 Tooling Design Guidelines (4004.001)

SLS CFR ESD PEKK Topology Optimization Guidelines (4006.001)

Integrated AM and Secondary Machining Support Guidelines (4029.001)

FDM ULTEM 9085 Part Design and Build Path Guidelines (4003.001)

Design for Additive Manufacturing Criteria and Analysis Tools (PC 3)

CFR Polymer CAD/CAM/CAE Optimization Tools (PC 3)

Material-Process Selection Design Advisors (PC 3)

Rule-Based DFM Methods & Algorithms (v1.0)

CAD Linkable Expert Design Advisors (v1.0)

Additive Manufacturing vs. Conventional Process Trade-Off Criteria (PC 3)

Process Map Based Machine Set-Up and Programming (PC 3)

Design Specification Query Algorithms (v1.0)

Automatic Generation of Process/Material/Machine Compliance Matrices (v1.0)

2018

2020

2019

Design Advisors that Recommend Rapid Qual/Cert Approaches (v1.0)

2013

2014

2015

2016

2017

2018

2020

2019

EBM Ti-64 & Co-Cr PV Process Maps (4009.001)

“Non Ad Hoc” Additive Manufacturing Tech Data Packages (8 Ideas)

DMLS Ti-64 & Co-Cr PV Process Maps (4009.001)

LENS Ti-64 & IN718 Process Window Characterization (4023.001)

EB-DED Ti-64 Microstructure for Ultrasonic NDI (4034.001)

Metallic Alloy Process Variable to Process Outcome Maps (PC 3)

Non-Metal Process Variable to Process Outcome Mapping (PC 3)

Process Specific Defect & Instability Boundary Mapping (PC 3)

Post-Processing Guidelines for Microstructure Optimization (PC 3)

Material Property Characterization (12 Ideas)

FDM ULTEM 9085 B-Basis Allowable Data (4003.001)

SLS CFR ESD PEKK B-Basis Design Allowable Data (4006.001)

EBM Ti-64 & Co-Cr Wire Feedstock Effects on Microstructure (4009.001)

DMLS Ti-64 & Co-Cr Powder Feedstock Effects on Microstructure (4009.001)

SLS PEKK Characterization (4020.001.6)

SLS Cu Characterization (4020.001.9)

EBM Ti-64 & Co-Cr Feedstock to Property Relationships (4028.001)

DMLS Ti-64 & Co-Cr Feedstock to Property Relationships (4028.001)

EBM Ti-64 B-Basis Allowable Development (4033.001)

Conductive Ink-Ceramic Material Compatibility/Adhesion (PC 3)

Standardized Feedstock Specifications for Tungsten Alloys (PC 3)

"As-Built" Tungsten Alloy Material Property Characterization (PC 3)

Next-Gen Materials (10 Ideas)

SLS CFR ESD PEKK Recyclability Guidelines (4006.001)

Low Cost Recycled Al Material Specifications (4024.001)

Forging Tool Wear Resistant Coating Guidelines (4020.001.5)

Biocompatible/Bioabsorbable Binder-Jet Fe-Mn (4031.001)

High-Temp Fireable Conductive Inks for Ceramic Substrates (PC 3)

Conductive Ink Rheology Optimization for improved Adhesion (PC 3)

High-Flowability Low-Temp Ink Rheologies for High AR Vias (PC 3)

Harsh Environment High Durability Conductive Ink Chemistries (PC 3)

High Melting Point Tungsten Alloy Development (PC 3)

Material Recyclability Indices (v1.0)

Materials Level 2 Roadmap

Maturation Needs

Roadmap v2.0 Update – Level 2

2013

2014

2015

2016

2017

2018

2020

2019

Multi-Material Delivery & Deposition (2 Ideas)

Adaptable Chemistry Conductive Ink Print Heads (PC 3)

3D-Gradient Material Deposition Control (v1.0)

Next-Gen Machines (9 Ideas)

Modular LENS Machine Tool Retrofit Systems (4022.001)

Low Cost Recycled Aluminum Desktop Printer (4024.001)

Micro-Induction Sintering Test Bed (4035.001)

High-Throughput LHW Ni & Ti Processing (4032.001)

Hybrid AM and Subtractive Systems (4029.001)

90 Deg Bend Conductive Ink Nozzle Optimization (PC 3)

Conductive Ink Printing for 3D High AR Structures (PC 3)

5mm Line/Trace Resolution Ink Printing Machines (PC 3)

Open Source PLC Architectures (v1.0)

Process Temperature Gradient Control Systems (2 Ideas)

Multi-Power Source Deposition & Thermal Management Systems (PC 3)

Real-Time Processing Temperature Analysis Methodologies (v1.0)

Process Level 2 Roadmap

Maturation Needs

Roadmap v2.0 Update – Level 2

IR Imaging for Laser PBF Thermoplastics (4042.001)

2013

2014

2015

2016

2017

2018

2020

2019

Advanced Sensing & Detection Methods (6 Ideas)

In-Situ Laser PBF Defect Monitoring Sensor Test Bed (1082.000 EWI)

Layer-by-Layer 3D Quality Certificates (1082.000 UofL)

3D Visualization Methods for Thermal Imaging Data (4008.001)

Multi-Sensor Thermal Imaging Systems for EBM & LENS Processes (4008.001)

High Accuracy Fast Response Quality Sensing (PC 3)

3D Melt Pool Temp Distribution Measurements (PC 3)

3D Visualization Tools for Real-Time QA Monitoring (PC 3)

Digital Thread Integration (2 Ideas)

MBE Methods for Integrated AM & Secondary Machining (4029.001)

Real-Time "As-Designed" vs. "As-Built" Tolerance Comparisons (v1.0)

Intelligent Machine Control Methods (6 Ideas)

Process Map Microstructure Control Algorithms (4008.001)

Distortion Compensation Control Algorithms (4026.001)

Integrated AM & Secondary Machining Control (4029.001)

Thermal Imaging Control of Laser PBF Thermoplastics (4042.001)

Real-Time In-Situ Defect Rework Control Algorithms (PC 3)

Model-Based Closed Loop Feedback Control Algorithms (v1.0)

Rapid Inspection Technologies (5 Ideas)

In-Situ QA Methods for Superalloy Laser PBF (4027.001)

NDE Post-Build Inspection of Laser PBF (1082.000 CTC)

Ti & Ni Alloy X-Ray CT NDI Procedures (4043.001)

Repair Technologies (2 Ideas)

H13 Die Cast Tooling Repair & Rejuvenation Guidelines (4007.001)

Laser Powder Directed Energy Part Repair Methods (4037.001)

Standards/Schemas/Protocols (11 Ideas)

NIST Round Robin Protocols (5 Standards)

Open Laser PBF Control Protocols (4039.001)

EB-DED Ti-64 Ultrasonic NDI Protocols (4034.001)

Industry Specific Qual/Cert Protocols (v1.0)

Third Party Data Capture Templates (v1.0)

Shared Data Repository Schemas (v1.0)

Data Repository Card Catalog & Pedigrees (v1.0)

Value Chain Level 2 Roadmap

Maturation Needs

Roadmap v2.0 Update – Level 2

EBM Al Process Modeling (4020.001.1)

2013

2014

2015

2016

2017

2018

2020

2019

Benchmark Validation Use Cases (4 Ideas)

Ti & Ni Alloy X-Ray CT NDI Reference Test Coupons (4043.001)

EB-DED Ti-64 Ultrasonic NDI Test Coupons (4034.001)

Reference NDI Test Coupons for Microstructure Control (PC 3)

Experimental Metallic Alloy Melt Pool & Distortion Data (PC 3)

Model-Assisted Property Prediction (2 Ideas)

CFR ULTEM Reduced Order Property Prediction Tools (PC 3)

ICME & Data Repository Statistical Model Links (v1.0)

Physics-Based Modeling & Simulation (8 Ideas)

Laser PBF Al Process Modeling (4020.001.1)

DMLS Numerical Simulation Methods (4020.001.4)

LENS Ti-64 ABAQUS FEA Set-Up Scripts (4020.001.11)

Laser PBF Ni, Co, and Ti Distortion Modeling (4026.001)

Laser PBF Ni, Ti, Co-Cr Melt Pool & Solidification Modeling (PC 3)

Tungsten Melt Pool, Solidification, & Distortion Modeling (PC 3)

M&S Tools for FDM Chopped Fiber Orientation Prediction (PC 3)

AM Genome Level 2 Roadmap

Maturation Needs

Roadmap v2.0 Update – Level 2

Next Steps

America Makes Teaming Interest

Indicate your interest in participating in an America Makes Proposal Team

Recommend potential

participants (members and/or non-member)

Current Capabilities and Relevant Work

Indicate current capability aligned to ONR QUALITY MADE Program Objectives

Indicate current projects (America Makes or Non-America Makes) aligned to ONR QUALITY MADE Program Objectives

Submit Responses to Rob Gorham by Friday, September 11, 2015

When America MakesAmerica Works

@

AmericaMakes

AmericaMakes.us