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NAMII Initiative 2013 Part1
The document summarizes a meeting of the National Defense Industry Association's Manufacturing Division that discussed establishing a pilot institute for the National Network for Manufacturing Innovation. Dr. Jennifer Fielding and Ed Morris presented on the National Additive Manufacturing Innovation Institute (NAMII), a public-private partnership led by the National Center for Defense Manufacturing and Machining. NAMII would establish shared additive manufacturing facilities and technology to bridge the gap between research and production. The summaries highlighted benefits of additive manufacturing for national defense and commercial applications.
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NAMII Initiative 2013 Part1
- 1. National Defense IndustryAssociation (NDIA) - Manufacturing Division Meeting 20-21 February 2013 Dr. Jennifer Fielding Program Manager, NAMII Deputy Program Manager, Defense-wide Manufacturing S&T Program AFRL/RXMS [email protected] Distribution A: Cleared for Public Release # 88ABW-2012-5792 A Pilot Institute for the National Network for Manufacturing Innovation (NNMI) Ed Morris Director, NAMII Vice President, NCDMM [email protected]
- 2. Outline PART I • Background •NAMII Vision • Why a Public-Private Partnership? • Why Additive? – DoD, DOE, NASA Benefits – Commercial applications – Maker / DIY manufacturing movement • Intermission PART II • NCDMM-led team • Technology Plan • Governance Structure • Technology Incubation Hub • Community Engagement and Membership • Project Call • Summary Distribution A: Cleared for Public Release # 88ABW-2012-5792
- 3. I. Enabling Innovation 1.Establish a National Advanced Manufacturing Strategy 2. Increase R&D Funding in Top Cross-Cutting Technologies 3. Establish a National Network of Manufacturing Innovation Institutes 4. Enhance Industry/University Collaboration in Advanced Manufacturing Research 5. Foster a Robust Environment for Commercialization of Adv Mfg Technologies 6. Establish a National Advanced Manufacturing Portal II. Securing the Talent Pipeline 1. Correct Public Misconceptions about Manufacturing 2. Tap the Talent Pool of Returning Veterans 3. Invest in Community College Level Education 4. Develop Partnerships to Provide Skills Certifications and Accreditation 5. Enhance Advanced Manufacturing University Programs 6. Launch Advanced Manufacturing Leadership Fellowships & Internships III. Improving the Business Climate 1. Enact Tax Reform, Streamline Regulatory Policy 2. Improve Trade Policy, Energy Strategy Background: Advanced Manufacturing Partnership (AMP) “Top Line” Recommendations* *AMP Final Report: “Capturing Domestic Competitive Advantage in Advanced Manufacturing” (July 2012): www.whitehouse.gov/sites/default/files/microsites/ostp/pcast_amp_steering_committee_report_final_july_17_2012.pdf Distribution A: Cleared for Public Release # 88ABW-2012-5792
- 4. Background: National Networkfor Manufacturing Innovation (NNMI) and Pilot Institute Announcement • Proposed one-time, $1B investment (FY13) for up to 15 Institutes of Manufacturing Innovation • Close the gap between R&D and deployment of technological innovations in domestic production of goods President Obama at Rolls-Royce Crosspointe Petersburg, VA – March 9, 2012 “institutes of manufacturing excellence where some of our most advanced engineering schools and our most innovative manufacturers collaborate on new ideas, new technology, new methods, new processes.” Distribution A: Cleared for Public Release # 88ABW-2012-5792 “We Can’t Wait” – use existing resources and authorities to demonstrate concept through a pilot institute – select competitively – fit within agencies missions
- 5. • A Defense-wideManufacturing S&T team-led, Multi-agency collaboration between industry, government and universities • Public-private partnership • Shared facilities open to industry ― Especially attractive to small businesses • Enabling technology transition and commercialization • Addressing Technology Readiness Level (TRL) / Manufacturing Readiness Level (MRL) 4-7 – Bridge the gap in Manufacturing Innovation • Educational plan to train the future workforce • Sustainable within 3 years A Model for Manufacturing Innovation Institutes within NNMI Distribution A: Cleared for Public Release # 88ABW-2012-5792
- 6. VISION: Widespread Adoption ofAdditive Manufacturing Innovators: • Full time applied researchers • Faculty/students in residence • Engineers • Entrepreneurs Shared Infrastructure: • Additive Mfg Equipment • Design & Simulation • Part Testing • Demonstration Links: • Manufacturing Extension Partnerships • Other Mfg Innovation Institutes • International community Public Sector Federal agencies National labs States Private Sector “Voice of the Customer” Large Industry Small Businesses Entrepreneurs Education Sector Research universities Community colleges Secondary schools • Greater Economic Competitiveness • New and better products and manufacturing technologies • Spin-off Companies • Highly Skilled Workforce Distribution A: Cleared for Public Release # 88ABW-2012-5792 “Industrial Commons”* – collective R&D, engineering, and manufacturing ability that can sustain innovation Invent stuff, make stuff and train the next generation *Harvard Business Review, Pisano and Shih
- 7. Streamlined Schedule toAward Date(s) Event 9 Mar 2012 Presidential Announcement of NNMI and a pilot institute 13 Apr 2012 Public Announcement of upcoming BAA 8 May 2012 Broad Agency Announcement (BAA) launched 16 May 2012 Proposer's Day (Q&A) 14 Jun 2012 Proposals Due 19-21 Jun 2012 Multi-agency team proposal evaluation and selection 16 Aug 2012 Award Announcement for NAMII 26 Nov 2012 First Project Call Announced 31 Jan 2013 Project Proposals Due 1 Mar 2013 Projects Announced 2-3 April 2013 NAMII Program Review and Project kick-off Distribution A: Cleared for Public Release # 88ABW-2012-5792
- 8. Why Do Public-PrivatePartnerships? • Better use of resources, cost savings • Industry and government both show a commitment – Not just issuing grants or formal contracted R&D • Tackle hard problems that can’t be done by one organization – Results are important to all – What are the big hurdles to overcome for Additive Mfg to move the industry into mainstream manufacturing? We need to have good reasons for collaborating…. because it is NOT EASY! Distribution A: Cleared for Public Release # 88ABW-2012-5792
- 9. Tenets of SuccessfulPublic-Private Partnerships High Stakes • Huge opportunity for AM • Economic revitalization • Model for NNMI Relationships • Open and Trusting • Transparency • Collaborative Leadership Reference: Working Across Boundaries: Making Collaboration Work in Government and Non-profit Organizations (R. Linden, 2002) The Basics/Framework • Shared Purpose • Champions with credibility/clout • Pooled resources • Open, credible processes • Coop Agreement, Statement of Work, Mgmt Structure • Program Op Plan, Perf Metrics, Roadmapping, Project Call Process Constituency for Collaboration Government, Industry, Universities, Community Colleges, Econ Dev Orgs Distribution A: Cleared for Public Release # 88ABW-2012-5792
- 10. Projected AM Sales(products and services) “20% of output of 3D printers is now final products, rather than prototypes. By 2020 it may be 50%.” – The Economist (2011) Why Additive? A Manufacturing Revolution! $B Government agency investments and interest - throughout NASA, DoD, and DOE Distribution A: Cleared for Public Release # 88ABW-2012-5792 Consumer Product Market
- 11. What is AdditiveManufacturing? • ASTM 2792-12: Process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies, such as traditional machining. Synonyms include additive fabrication, additive processes, additive techniques, additive layer manufacturing, layer manufacturing and freeform fabrication • Deposit material where the object “is” rather than where the object “isn’t” • Trending layperson synonym for all types of additive manufacturing: 3D Printing Distribution A: Cleared for Public Release # 88ABW-2012-5792
- 12. Traditional Defense ManufacturingIssues • “Traditional” materials processing methods are slow and cumbersome – Tooling remains expensive and have long lead times – Last minute design changes are difficult and costly • Complex structures are difficult to engineer and assemble • Small, intricate geometries and porous geometries are difficult to manufacture using conventional processes Many designs are constrained by manufacturing process limitations Distribution A: Cleared for Public Release # 88ABW-2012-5792
- 13. DoD Benefits ofAdditive Manufacturing Efficient use of Resources Fewer processing steps, net-shape, less assembly, post-processing, less waste material, less energy Small lot productions Production in lot size of 1, mass customization Rapid manufacturing Tool-less, extreme cycle time reductions Agile Manufacturing Spare parts on demand, no stockpiles, simplified supply chain / logistics Reverse Engineering Scan and manufacture parts for legacy systems Cost Reduction Expendable / Disposable products Lightweight Structures Weight removal increases mission capabilities Modularity New Designs to switch components in and out Complexity Exotic structures, Functionally-graded materials, fabricate moving joints, embedded electronics Revolutionary Production Enabling New Technology Distribution A: Cleared for Public Release # 88ABW-2012-5792
- 14. DoD/NASA Benefits ofAdditive 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 Distribution A: Cleared for Public Release # 88ABW-2012-5792
- 15. Department of DefenseApplications • High value, complex parts • Low and medium volume part production • Legacy parts and electronics • Remote, mobile fabrication • Custom medical implants and devices Custom cranial plates – Walter Reed Distribution A: Cleared for Public Release # 88ABW-2012-5792
- 16. • Sustainability • Newproducts for energy applications supported by Additive Manufacturing technologies – Wind turbines: 8,000 high value parts – Vehicle lightweighting • Manufacturing process energy reductions and efficiencies Department of Energy Applications Distribution A: Cleared for Public Release # 88ABW-2012-5792
- 17. Commercial Market: MassCustomization Spin-off Companies New Markets GDP Growth Distribution A: Cleared for Public Release # 88ABW-2012-5792
- 18. Reference: Makers: TheNew Industrial Revolution (Chris Anderson, 2012) The Maker Movement: The Democratization of Manufacturing? • Idea of a “factory” is changing • New class of desktop manufacturing equipment is democratizing manufacturing innovation • Shifting to both “small and global”, “high-tech and low cost”, “artisanal and innovative” • Bottom-up, broadly distributed, highly entrepreneurial • Sharing and open source philosophy • 3D Printing is akin to the PC revolution in 1985? Distribution A: Cleared for Public Release # 88ABW-2012-5792 Replicator 2 (2013)
- 19. • Growth ofEtsy - Web marketplace for Makers • 2011 – $500 M of sales from nearly 1M sellers • Over 2,000 3D printed items DIY Manufacturing and Entrepreneurship Recent Trends Popularity of “Make” Magazine 3D Printing file sharing and marketplaces Crowd-sourced Investing Platforms: Distribution A: Cleared for Public Release # 88ABW-2012-5792
- 20. • Sponsored by“Make” magazine to "celebrate arts, crafts, engineering, science projects and the DIY mindset • > 100k in attendance Distribution A: Cleared for Public Release # 88ABW-2012-5792 Maker Faire - DIY Movement: Making Creation and Manufacturing Cool
- 21. Educational Outreach andWorkforce Development • Start them young! • Encourage creativity and exploration • Have kids teach other kids • Teach parents and teachers Distribution A: Cleared for Public Release # 88ABW-2012-5792 TechFest, 2013 Sinclair Community College Dayton, OH 15 – 16 Feb 2013 Air Force ManTech booth MakerBot and UAV display
- 22. Distribution A: Clearedfor Public Release # 88ABW-2012-5792
- 23. INTERMISSION Distribution A: Clearedfor Public Release # 88ABW-2012-5792
- 24. Announcement: Aug 16,2012 Prime Awardee: National Center for Defense Mfg. & Machining (NCDMM) • Providing ~$40M cost share ~ $20M from industry ~ $48M available for projects • Strong leveraging of equipment and existing resources • Strong business development • Ties to many organic facilities • Tiered membership-based model Distribution A: Cleared for Public Release # 88ABW-2012-5792
- 25. Distribution A: Clearedfor Public Release # 88ABW-2012-5792 A REGIONAL Center of Excellence, with a vision for NATIONAL PRESENCE
- 26. NAMII Initial Partners DistributionA: Cleared for Public Release # 88ABW-2012-5792
- 27. Present NAMII Consortia DistributionA: Cleared for Public Release # 88ABW-2012-5792
- 28. Projected NAMII Consortiain 18 months *based on 2012 Wohlers Report of active AM organizations and discussions to date Distribution A: Cleared for Public Release # 88ABW-2012-5792
- 29. Strong, Holistic, IntegratedTechnology Plan • Process development: metals, polymers, ceramics, electronics, hybrid • Digital thread / AME • Specialized, portable AM systems • Open Architecture • Process planning • Process Control • Material Development • Component Design Distribution A: Cleared for Public Release # 88ABW-2012-5792
- 30. Governance Structure –Shared Leadership Director Deputy Director: Technology Development • Facility Management • Project Management • IP Management Deputy Director: Advanced Manufacturing Enterprise • SME Coordination • Incubation/Commercialization • Supply chain and design modeling • Digital Thread • Sustainability 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 (12 gov’t members) Link to Gov’t Agencies, Technical Strategy, Program Operating Guidance OSD ManTech (Mfg and Ind. Base Policy) Gov’t Co-op Agreement Program Manager 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: All 1st and 2nd Tier Members, small business, MEP director members, states ex-officio = Direct Oversight/Responsibility = Guidance / Direction
- 31. Technical Advisory Board(TAB) Members Subject Matter Experts in AM • Eric Brown, Army • Bill Frazier, Navy • Steve Szaruga, Air Force • Tony Monteleone, DLA • Ken Wetzel, OSD MIBP • Mick Maher, DARPA • Will Joost, DOE • Stephen Sikirica, DOE • Kelly Visconti, DOE • Kevin Jurrens, NIST • Zhijan (ZJ) Pei, NSF • Catharine Fay, NASA • Lanetra Tate, NASA Distribution A: Cleared for Public Release # 88ABW-2012-5792
- 32. Executive Committee Members •Jim Williams, 3D Systems • Eric Barnes, Northrop Grumman • Gary Fedder, Carnegie Mellon University • Jim McGuffin-Cawley, Case Western Reserve University • Tim Shinbara, Association for Manufacturing Technology • Mark Tomlinson, Society of Manufacturing Engineers • Tom Stimson, The Timken Company • John Russell, Air Force Research Laboratory, (DMS&T Program Manager) • Rob Ivester, Department of Energy • Bruce Kramer, National Science Foundation Distribution A: Cleared for Public Release # 88ABW-2012-5792
- 33. Technology Incubation Hub(9/27 Ribbon Cutting) Youngstown Business Incubator Annex Building Distribution A: Cleared for Public Release # 88ABW-2012-5792
- 34. NAMII Technology IncubationHub Youngstown OH – America’s Heart of Manufacturing • Youngstown Business Incubator • Downtown Youngstown - vibrant, revitalized location – Rich history of manufacturing and incumbent labor pool with manufacturing background • Geographic center of band of manufacturing activity stretching approximately from Cleveland region through Pittsburgh region – Roughly 50% of the U.S. population lives within 500 miles • Region is well-poised for economic rebirth – Steel industry is being reborn (2010 V&M Star plant expansion) – High technology, advanced manufacturing – Focal point for entrepreneurs Distribution A: Cleared for Public Release # 88ABW-2012-5792
- 35. AM Equipment EntrustedTo Date 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 Direct Metal Deposition POM Synergy 5 Material Extrusion (3D Printer) 3DCAD Printer Hyrel Plunge / "Dry" EDM Sodick (w/ POM Upgrades) AQ55L Ancillary/support equipment: CNC milling machine, ovens, chillers, etc. Distribution A: Cleared for Public Release # 88ABW-2012-5792
- 36. Engaging the community… DistributionA: Cleared for Public Release # 88ABW-2012-5792
- 37. Current Members • 3DSystems Corporation • Abbatron • Allegheny Technologies • Association of Manufacturing Technology • APEX CNC Swiss • AST2 • Automated Dynamics • Bayer Material Science • BenFranklin C&N PA • BenFranklin SE PA • BioDevice Design • Boundry Systems • Case Western Reserve University • Catalyst Connection • Concurrent Technologies Corporation • DVIRC • Energy Industries of Ohio • The ExOne Company • FMW Composites • Fourth Economy • GE Global Research • Greenleaf • Innovation Works • IRC Network, Inc. • JumpStart • Kennametal • Kent Display • Kent State University • Lehigh University • Liquid X Printed Metals • Lockheed Martin Aeronautics • Lubrizol • M-7 Technologies • MAGNET • Manufacturing Resource Center (MRC) • Missouri University of Science and Technology • NE PA IRC • NorTech • Northern Illinois University • Northhampton Community College • Northrop Grumman • nScrypt • NorthWest IRC • Ohio Aerospace Institute • Optomec • OSRAM Sylvania • Oxford Performance Materials • Pennsylvania State University • POM • PTC ALLIANCE • Robert C. Byrd Institute (RCBI) • Robert Morris University • PTC ALLIANCE • Robert C. Byrd Institute (RCBI) • Robert Morris University • RTI • Society of Manufacturing Engineers • Stratonics • TechSolve • Thogus/RP+M • The Timken Company • Touchstone Research Lab • University of Akron • University of Texas – Austin • University of Texas at El Paso • University of Toledo • Westmoreland County Community College • Wohlers Associates • Wright State University • Youngstown Business Incubator • Youngstown State University Distribution A: Cleared for Public Release # 88ABW-2012-5792
- 38. Leveraging America’s VOICe •Establishing Additive Manufacturing EcoSystem • Developed AM Ontology • Cataloging member capabilities in company profiles • Capability search • Opportunity posting and sourcing • Virtual collaboration & partnering Distribution A: Cleared for Public Release # 88ABW-2012-5792
- 39. Membership is Open •Full Member* – A seat on the NAMII Governance Board – Royalty free non-exclusive rights for commercial development for all NAMII IP – Ability to embed one Lead Member employee into the NAMII facility free – Supporting Membership for SME supplier of the Lead Member’s choice • Lead Member* – A seat on the NAMII Governance Board – Ability to embed Full Member employees into the NAMII facility after paying an additional overhead fee per employee – Non-royalty free Non-exclusive rights for commercial development for all NAMII IP • Supporting Member* – Ability to schedule R&D and first-article production access of the NAMII infrastructure on a fee-for-service basis at the time of use * Sampling of Member Benefits More info at: namii.org Distribution A: Cleared for Public Release # 88ABW-2012-5792
- 40. Project Call #1Topic Areas • Qualification & Certification – Rapid qualification and certification methods – Leverage modeling and simulation – Quantification of process variability – Variability reduction to increase reliability, process optimization, rate increases – Certification of suppliers NAMII project efforts focus on TRL/MRL 4-7 *Not Basic Research* Distribution A: Cleared for Public Release # 88ABW-2012-5792
- 41. Project Call #1Topic Areas • Materials Understanding and Performance – Materials database designs – Design allowable properties for materials – Data access and sharing – Materials variability and management – Material requirements/gaps identification NAMII project efforts focus on TRL/MRL 4-7 *Not Basic Research* Distribution A: Cleared for Public Release # 88ABW-2012-5792
- 42. Project Call #1Topic Areas • Process Capability and Characterization – Process repeatability and throughput improvement – Develop algorithms for modeling expected outcomes – Improved part quality – In-situ adaptive control systems NAMII project efforts focus on TRL/MRL 4-7 *Not Basic Research* Distribution A: Cleared for Public Release # 88ABW-2012-5792
- 43. Project Call KeyCriteria • Project Lead must be NAMII Consortium Member • Project teams – SME involvement stressed • Diverse team expertise (technical, business development, education) • 50/50 Cost share • Strong technical approach • Sound transition plan • Advanced Mfg. Enterprise & Workforce/Education elements • Reasonableness and realism of the proposed cost, proposed cost share, and schedule Distribution A: Cleared for Public Release # 88ABW-2012-5792
- 44. Schedule • Project Call#1 award announcement: 1 March 2013 • Program Review and project kick-off 2-3 April 2013 • Project Call #2 June 2013 More info at: namii.org/projects Distribution A: Cleared for Public Release # 88ABW-2012-5792
- 45. Recent Public Acknowledgements “Stateof the Union” – 12 Feb 2012 “Last year, we created our first manufacturing innovation institute in Youngstown, Ohio. A once- shuttered warehouse is now a state-of-the-art lab where new workers are mastering the 3D printing that has the potential to revolutionize the way we make almost everything.” Brookings Institute / Rockefeller Foundation This year’s list of “Innovations to Watch” represents the most forward-thinking and effective solutions that are now being implemented by America’s states and metropolitan areas Distribution A: Cleared for Public Release # 88ABW-2012-5792
- 46. Summary • NAMII showsan unprecedented level of collaboration on manufacturing technology across government, industry and universities • Huge opportunity and high stakes • Establishing the framework for continued success • Capturing Best Practices and Lessons Learned – Model for the NNMI • Encourage this community to be involved Distribution A: Cleared for Public Release # 88ABW-2012-5792
- 47. Distribution A: Clearedfor Public Release # 88ABW-2012-5792