America Makes - Smart Collaboration

1. AmericaMakes.us
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Smart Collaboration
Leverage a rich knowledge base to gain competitive
advantage in the additive manufacturing industry
Rob Gorham
America Makes
Director of Operations
Rodrigo Enriquez
America Makes
Factory Engineer

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National Center for Defense and
Manufacturing and Machining (NCDMM)
Delivering Manufacturing Innovation
 Established 2003
 Non-profit
 Manufacturing Solution Provider
 Independent, Unbiased
 Project-Based (~100 active projects)
 Improve Cost, Quality, Performance
 Rapid Deployment to Industry and the
Warfighter
 America Makes Administrator
Collaborate…
…with government, industry, and academia to
promote best practices, and deliver them to key
stakeholders…we “connect the dots”

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Why NNMI, Why America Makes?
The foundation is laid – in March 2012, the formation of a National
Network for Manufacturing Innovation (NNMI) was proposed and America
Makes (National Additive Manufacturing Innovation Institute) was launched in
August as the initial Institute of Manufacturing Innovation (IMI).
The vision is simple – leverage our nation’s brilliant technical minds
in all corners of government, industry and academia to accelerate the
adoption of additive manufacturing technologies in the U.S. manufacturing
sector and increase domestic manufacturing competitiveness.
The goal is bold – create truly collaborative environments to bring
technology advancements from the lab to the factory floor, create jobs,
produce more competitive products, and ultimately reaffirm our place
in the global market.

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Who We Are
Public / Private Partnership
America Makes has substantial federal, private industry,
and academic investment.
Multi-Agency Collaboration
Partnership between industry, government and universities,
led by the Defense-wide Manufacturing S&T team.
Membership
Innovation facility in Youngstown, Ohio with150 members.
We continue to grow.
Operations
We are operated by the National Center for Defense
Manufacturing & Machining (NCDMM)

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Our Purpose
Our main goal is to “Bridge the Gap”
and address Technology & Manufacturing Readiness
Levels (TRL & MRL) 4-7 enabling technology transition
and commercialization through funding innovation projects.
Government &
Universities Private Sector
TRL & MRL
4–7
Invention Commercialization

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Widespread adoption of AM depends on organizations developing AM
capabilities, not just purchasing machines
Focus: Robust, Sustainable Value Chain

7. AmericaMakes.us
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Collaborate, Cooperate, Innovate
Technology
Development
Technology
Transition
Workforce
and
Educational
Outreach

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How We Approach Innovation
Project Funding – We competitively award projects
to members using public and private funds, addressing prioritized
topics on our member-driven technology roadmap.
Our Vast Network – We act as a connector and facilitator
between all of our members. Everyone has a seat at the table
to contribute and collaborate with us and one another.
Workforce Readiness – Training and educational outreach
is a priority for the institute. Every Public/private funded
project requires an educational outreach component.
Technology Transition – We make it real. Every public/private
funded project requires a pilot transition component.

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America Makes Roadmapping
 America Makes has released v2.0 of the
Technology Roadmap using a systems
engineering-based methodology
 America Makes has partnered with Deloitte on
a shared vision for growing from technology
development to capability development
 Execute a continuous Systems Engineering-
based approach to roadmap development,
anchored by in-person workshops featuring a
suite of enhanced facilitation techniques

10. AmericaMakes.us
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Swim Lane CRITICAL TECHNOLOGY ELEMENT
Project Call
Topic
Design
Bio-Inspired Design & Manufacturing
Cost & Energy Driver Analysis/Modeling
Product & Process Design Aides/Apps Project Call Topic
Material
Additive Mfg Tech Data Packages Project Call Topic
Material Property Characterization Project Call Topic
Next-Gen Materials Project Call Topic
Process
Multi-Material Delivery & Deposition Project Call Topic
Next-Gen Machines Project Call Topic
Process Temperature Gradient Control Project Call Topic
Value Chain
Advanced Sensing & Detection Methods Project Call Topic
Intelligent Machine Control Methods Project Call Topic
Digital Thread Integration
Rapid Inspection Technologies
Repair Technologies
Standards/Schemas/Protocols
AM Genome
Benchmark Validation Use Cases Project Call Topic
Model-Assisted Property Prediction Project Call Topic
Physics-Based Modeling & Simulation Project Call Topic
Standard Feedstock Materials, Benchmark Property
Data, Microstructure Relationships, Process Window
Definition, Processing Guidelines & Specifications
Complexity Exploitation, 3D Graded Materials, Multi-
Material Integration, Model-Based Development,
Product Customization
Faster Build Speeds, Improved Surface Quality, Larger
Part Envelopes, Improved Detail Capability
Material Costs, Processing Costs, Quality Control
Costs, Productivity Costs, Energy Efficiency Costs
Concurrent Methods, Computational Tools,
Experimental Tools, Modular Open Simulations, Open
Multi-Scale Data
Impact Focus

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America Makes Technology Roadmap –
Level 1resented at Fall 2014 PMR)
2014 2015 2016 2017 2018
Process
Material
AM Genome
Value Chain
Standards/Schemas/Protocols
Design
Repair Technologies
Advanced Sensing and Detection Methods
Intelligent Machine Control Methods
Digital Thread Integration
Rapid Inspection Technologies
Multi-Material Delivery & Deposition Systems
Next-Gen Machines
Process Temp Gradient Control
Material Property Characterization
Next-Gen Materials
“Non Ad-Hoc” Additive Manufacturing Tech Data Packages
Product & Process Design Aides/Apps
Cost & Energy Driver Analysis/Modeling
Bio-Inspired Design & Manufacturing
Model Assisted Property Prediction
Benchmark Validation Use Cases
Physics-Based Modeling & Simulation

12. AmericaMakes.us
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Workforce and Education Mission
 Engage industry to address needs/skill gaps
 Create a Project Based Learning Environment
 Attract and Develop Students Through Multi-Modal and Hands On
Experiences
 Attract and Educate Teachers, Faculty and Instructors on AM
 Integrate AM into existing curriculum and STEM efforts
 Build a process to create certifications, credentialing, 2+2+2
programs articulation agreements.
 Provide professional education on AM

13. AmericaMakes.us
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WEO Roadmap Definitions

14. AmericaMakes.us
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WEO Roadmap v1.0 Level One View

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Our approach to IP
CONSERVE  INTEGRATE  TRANSITION
You Own Your IP – You will own both
pre-existing IP and any you develop through
consortium effort.
We Provide Protection – We have a membership
agreement in place that is designed to protect your
interests by ensuring that all participants play by
the same set of rules.
Increase Chances of IP Adoption – We facilitate
IP transition through our project-based approach
and expansive network that represents multiple
industries, markets, and stakeholders.
All Consortium
Developed IP is owned
by the inventing
organizations–
We help to conserve,
integrate, and transition.

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17. AmericaMakes.us
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The Innovation Factory
8 WAYS MEMBERS CAN ENGAGE THE YOUNGSTOWN FACILITY
Demonstrations &
one-off prototyping
Training on
equipment &
techniques
Showcase
your projects,
equipment,
concepts
House employees
at the innovation
factory
Education events
(camps, training)
Workshop space
for technical &
general meetings
Fabrication
and support
capabilities &
services
Technology
validation

18. AmericaMakes.us
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Current Technology
FORTUS 400mc FDM Machine – Reliable. Flexible. Plastic
• Engineering
grade
thermoplastics:
ULTEM, Nylon,
Polycarbonate,
ABS
• Soluble and
Break-away
support for
complex and
fast build.
• Flexible size
build envelope.

19. AmericaMakes.us
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Current Technology
sPro 60 HD-HS SLS Machine – Collaboration. Customization. Plastic
• Engineering
grade
thermoplastics:
• No need for
support material
• Better surface
finish
• Industrial size
build envelope
• Fully Open
parameter setting
for America
Makes

20. AmericaMakes.us
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Current Technology
ExOne M-Lab – Collaboration. Customization. Metal
• Material process
development
• No need for
support material
• Metal parts
• Small cost
effective envelope

21. AmericaMakes.us
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Current Technology
ProX 320 SLM. Production. Safety. Flexibility.

22. AmericaMakes.us
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Project Example: Distortion Prediction
 Reduce the number of process iterations required to build a part using metal
powder-bed AM through fast & accurate thermo-mechanical distortion
prediction & pre-compensation of part geometry to mitigate distortion
 Accelerate the deployment of AM at large OEM’s and SME’s through reduced
development cost & optimal material usage
 In-depth validation of 2 competing, high-speed, accurate process distortion
prediction & compensation methodologies
Total project value: Approx. $2.25M
Project team: GE GRC, UTRC, Honeywell,
Pan Computing, LLC, University of Louisville,
Penn State University, CDI Corporation
Timeline: August 2014 – August 2016

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Project Example:

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Project Example:

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When America Makes
America Works
@AmericaMakesAmericaMakes.us