namii initiative 2013 part2

National Defense Industry Association (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 Jennifer.fielding@wpafb.af.mil

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 Ed.morris@ncdmm.org

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

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

Background: National Network for 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.”

“We Can’t Wait” – use existing resources and authorities to demonstrate concept through a pilot institute – select competitively – fit within agencies missions

• A Defense-wide Manufacturing 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

VISION: Widespread Adoption of Additive

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

“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

Streamlined Schedule to Award Competitive, project-level effort beginning within a year from

announcement of concept 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

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

Why Do Public-Private Partnerships?

• Better use of resources, cost savings • Industry and government both show a commitment

– Not just doling out grants or contracted R&D where

• Tackle hard problems that can’t be done by one organization – Results are important to all

Need to have good reasons for collaborating…. because it is NOT EASY!

Tenets of Successful Public-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

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

Consumer Product Market

What is Additive Manufacturing?

• 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

Traditional Defense Manufacturing Issues • “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

DoD Benefits of Additive 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

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

Department of Defense Applications

• 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

• Sustainability • New products 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

Commercial Market: Mass Customization

Spin-off Companies New Markets GDP Growth

Reference: Makers: The New 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 potentially akin to the PC revolution

in 1985?

Replicator 2 (2013)

• Growth of Etsy - Web marketplace for Makers • 2011 – $500 M of sales to

nearly 1M sellers • Over 2,000 3D printed items

DIY Manufacturing and Entrepreneurship Recent Trends

Popularity of “Make” Magazine

3D Printing sharing and selling sites:

Crowd-sourced Investing Platforms:

• Sponsored by “Make” magazine to "celebrate arts, crafts, engineering, science projects and the DIY mindset

• > 100k in attendance

Maker Faire - DIY Movement: Making Creation and Manufacturing Cool

Educational Outreach and Workforce Development • Start them young! • Encourage creativity and

exploration • Have kids teach kids • Teach parents and teachers

INTERMISSION

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

A REGIONAL Center of Excellence, with a vision for NATIONAL PRESENCE

NAMII Initial Partners

Present NAMII Consortia

Projected NAMII Consortia in 18 months *based on 2012 Wohlers Report of active AM organizations and discussions to date

Strong, Holistic, Integrated Technology 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

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

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

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

Technology Incubation Hub (9/27 Ribbon Cutting) Youngstown Business Incubator Annex Building

NAMII Technology Incubation Hub 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

AM Equipment Entrusted To 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

Engaging the community…

Current Members • 3D Systems 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

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

Membership is Open • Lead 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

• Full 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

Project Call #1 Topic 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

Project Call #1 Topic 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

Project Call #1 Topic Areas • Process Capability and Characterization

– Process repeatability and throughput improvement – Develop algorithms for modeling expected outcomes – Improved part quality – In-situ adaptive control systems

Project Call Key Criteria • 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

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

Recent Public Acknowledgements “State of 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

Summary • NAMII shows an 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

namii initiative 2013 part2

manufacturing ability

public release

publicprivate partnerships

nnmi distribution

new technology

correct public misconceptions

pilot institute announcement

project kickoff distribution

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