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

• 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.

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*

• Materials Understanding and Performance
– Materials database designs
– Design allowable properties for materials
– Data access and sharing
– Materials variability and management
– Material requirements/gaps identification

• 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

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

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NAMII Initiative 2013 Part2