Driven by… Driven by… Driven by… America Makes Project Call Kickoff Webinar Maturation of Advanced Manufacturing for Low Cost Sustainment (MAMLS), Phase 3 December 1, 2017 John Wilczynski America Makes, NCDMM Technology Director john.wilczynski@ncdmm.org Erin O’Donnell America Makes, NCDMM Program Coordinator erin.odonnell@ncdmm.org AmericaMakes.us AmericaMakes.us Approved for Public Release
Driven by… Project Call Summary ▪ Schedule ▪ Objective / Background ▪ Technical Topics / Funding ▪ Project Call Summary ▪ Project Call Process ▪ Step 1 : Project Concept ▪ Step 2 : Project Proposal Phase ▪ Evaluation Criteria ▪ Exhibits ▪ Nuances AmericaMakes.us AmericaMakes.us Approved for Public Release
Driven by… Schedule Event Date 1. Project Call Announcement and posting 11/27/2017 2. Questions from Proposers about Scope or Approach Due 12/15/2017 3. Responses to Proposers about Scope or Approach Due 12/19/2017 4. Fully Executed NDA with NCDMM (if proposal contains proprietary information) 12/22/2017 5. Project Concept Submission Due Date 01/03/2018 6. Anticipated Decision and Notification to Project Concept Teams who are being asked 01/17/2018 to Submit Full Proposals 7. Full Project Proposal Submission Due Date 02/23/2018 8. Anticipated Decision and Notification to Project Proposal Teams 03/21/2018 9. Anticipated Start Date of Projects 06/01/2018 AmericaMakes.us AmericaMakes.us Approved for Public Release
Driven by… Objective / Background - Detailed Objective: Phase 3 of the “Maturation of Advanced Manufacturing for Low-Cost Sustainment (MAMLS)” program is intended to address key challenges to insertion of AM technology for maintenance, sustainment, and logistics operations within the DoD that have been identified throughout Phases 1 and 2. Currently, these material, process, and post-process barriers are preventing greater penetration of AM technology for more challenging, safety critical applications or for the breadth of parts demand sought by the AF sustainment community. Background: MAMLS Phase 1 successfully developed advanced manufacturing solutions to sustainment needs for USAF and DoD customers at Warner Robins ALC, Ogden ALC, Oklahoma City ALC, 910 th Airlift Wing at Youngstown Air Reserve Station, and Navy FRC Cherry Point, primarily through successful transition of ground support equipment and process aids. MAMLS Phase 2 was launched in Spring 2017 and is focused on walking the path toward qualification for representative part families. Three parts were chosen for this task: bell crank family of parts to explore features of varying thicknesses on a flight critical component; oil-cooler family of parts to represent lightly loaded components with complex features and high functional requirements; and fairing family of parts to explore viability of material extrusion for core structure with composite sandwich panels. AmericaMakes.us AmericaMakes.us Approved for Public Release
Driven by… Objective - At a Glance Objective: ▪ Develop and demonstrate advanced manufacturing technologies related to additive manufacturing that improve rapid part replacement/maintenance for legacy aircraft. ▪ Enable on-demand replacement of critically damaged or obsolete components that do not meet economic requirements of conventional supply chains. ▪ Develop and demonstrate rapid fabrication of shop tools such as assembly aids, jigs, and fixtures for sustainment center utilization. ▪ Identify technology gaps and transition issues that need to be solved prior to effective implementation. ▪ Reduction of the cost and lead time to fabricate replacement components for legacy aircraft as well as for rapid tooling, masks, fixtures, etc. ▪ Technology demonstrations and learning for future implementations both in industry and AF organic sustainment operations. AmericaMakes.us AmericaMakes.us Approved for Public Release
Driven by… Technical Topics / Funding Availability NCDMM anticipates multiple awards, up to the available funding Technical Topic Title Funding Topic 1: Feature Based Qualification using Directed Not to exceed $2,500,000 in federal funding Energy Deposition Topic 2: Understanding Manufacturing Realities of Not to exceed $1,000,000 in federal funding AM: Effects of Defects Topic 3: Emerging Process Technology for Low Not to exceed $600,000 in federal funding Criticality Part Families AmericaMakes.us AmericaMakes.us Approved for Public Release
Driven by… Technical Topics: Topic 1 – FBQ using DED Feature Based Qualification using Directed Energy Deposition The goal of this topic area is to apply FBQ approaches to the production of large scale, additively manufactured aerospace components utilizing DED techniques. ▪ Demonstrate the extent of utility of the FBQ approach ▪ Identify associated implementation challenges and risk Analogy to Welding Procedure reduction or alternative qualification strategies. Specification AmericaMakes.us AmericaMakes.us Approved for Public Release
Driven by… Technical Topics: Topic 1 – DoD Roadmap Alignment Feature Based Qualification using Directed Energy Deposition Non-exclusive list of DoD AM Roadmap Elements which may be applicable: ▪ DoD.D.4 – Develop Design for Function Guidelines ▪ DoD.P.2 – Establish Stable and Robust AM Processes DoD.P.4 – Modify Existing or Develop New Process Capabilities ▪ ▪ DoD.V.2 – Develop Qualification and Certification Methods for Parts and Systems AmericaMakes.us AmericaMakes.us Approved for Public Release
Driven by… Technical Topics: Topic 2 – Effects of Defects Understanding Manufacturing Realities of AM: Lack of Effects of Defects Fusion Defect The goal of this topic area is to quantify the effect of defects on the mechanical performance of additively manufactured material. ▪ Evaluation of material properties that are sensitive to statistical extremes is of particular interest, as well as the evaluation of real flaws rather than having to make assumptions about the relevance of intentionally induced flaws, such as CAD-embedded voids. ▪ Characterizing the extent to which specific post-processing approaches, such as Hot Isostatic Pressing, improve mechanical performance is also relevant to this topic area. Gorelik M. Additive manufacturing in the context of structural integrity. Int J Fatigue (2016), http://dx.doi.org/10.1016/j.ijfatigue.2016.07.005 AmericaMakes.us AmericaMakes.us Approved for Public Release
Driven by… Technical Topics: Topic 2 – DoD Roadmap Alignment Understanding Manufacturing Realities of AM: Effects of Defects Non-exclusive list of DoD AM Roadmap Elements which may be applicable: ▪ DoD.D.1 – Enable Robust, Integrated, and Intelligent Design Tools DoD.M.1 – Define Standard AM Materials Requirements ▪ ▪ DoD.P.1 – Develop NDE and Process Control ▪ DoD.P.2 – Establish Stable and Robust AM Processes ▪ DoD.V.2 – Develop Qualification and Certification Methods for Parts and Systems AmericaMakes.us AmericaMakes.us Approved for Public Release
Driven by… Technical Topics: Topic 3 – Emerging Processes Emerging Process Technology for Low Criticality Part Families The goal of this topic is to evaluate the ability of emerging AM processing and AM technologies to supply low criticality components Some examples include, but are not limited to, unique electrical that satisfactorily fulfill the required part function. connectors, ducting, manifolds, instrumentation knobs, wiring AFRL seeks to assess the degree to which the demonstrated solutions harnesses, small brackets, and other non-critical end use items. Such parts may have identical function, but slightly different extend to part families of similar size, shape, criticality, and function. geometries or features that result in many variants of very similar parts. The following processes as defined by ASTM F2792 will be considered for funding under this program area: ▪ Highly loaded material extrusion – e.g. fiber, metal, ceramic ▪ Vat photopolymerization ▪ Powder bed fusion with non-laser and non-electron beam energy sources ▪ Sheet Lamination AmericaMakes.us AmericaMakes.us Approved for Public Release
Driven by… Technical Topics: Topic 3 – Emerging Processes Emerging Process Technology for Low Criticality Part Families Non-exclusive list of DoD AM Roadmap Elements which may be applicable: ▪ DoD.D.4 – Develop Design for Function Guidelines DoD.M.1 – Define Standard AM Materials Requirements ▪ ▪ DoD.V.1 – Build Cost Models and Decision Tools AmericaMakes.us AmericaMakes.us Approved for Public Release
Driven by… Project Call Summary ▪ $5,700,000 is being made available ▪ 24 months maximum period of performance • 22 months technical • 2 months reporting ▪ 50% cost share required ▪ Funding Breakdown per Topic area • Topic 1: $ 2.5M • Topic 2: $ 1.0M • Topic 3: $ 600K AmericaMakes.us AmericaMakes.us Approved for Public Release
Driven by… Project Call Summary – Project Call Steps AmericaMakes.us AmericaMakes.us Approved for Public Release
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