1. ADDITIVE MANUFACTURING: ENABLING ADVANCED MANUFACTURING NAE Convocation of the Engineering Professional Societies Washington, D.C. April 22, 2013 Tim Shinbara Technical Director AMT - The Association For Manufacturing Technology 1

2. Introduction Background Applications Paths-Forward NAMII Summary & Conclusion 2 Agenda

3. Introduction Background –Terminology –Technology Primer –Potential Benefits Applications Paths-Forward NAMII Summary & Conclusion 3 Agenda

4. 4 Background: Terminology Additive Manufacturing is Much More Than Just “Printing” “Direct Digital”… “Laser Additive”… “Direct Part Mfg”… …there are standards?

5. 5 ASTM F42 Sub-Committee on Terminology (F2792) 1. Binder Jetting an additive manufacturing process in which a liquid bonding agent is selectively deposited to join powder materials 2. Directed Energy Deposition an additive manufacturing process in which focused thermal energy is used to fuse materials by melting as they are being deposited 3. Material Extrusion an additive manufacturing process in which material is selectively dispensed through a nozzle or orifice 4. Material Jetting an additive manufacturing process in which droplets of build material are selectively deposited 5. Powder Bed Fusion an additive manufacturing process in which thermal energy selectively fuses regions of a powder bed 6. Sheet Lamination an additive manufacturing process in which sheets of material are bonded to form an object 7. Vat Polymerization an additive manufacturing process in which liquid photopolyme r in a vat is selectively cured by light-activated polymerization

6. Background: Technology Primer 6 Increase Product Potential, Reduce Waste (Time, Materials…Cost) Additive Manufacturing (AM) materials –Polymeric (Nylon, PAEK, ABS-like, etc.) –Metallic (Ti-alloys, CoCr, SS 17-4, etc.) –Composite, Ceramic, Paper-based AM enables smarter manufacturing –3D Art-to-Part via 2D layer-by-layer –Near-net, to net-shape parts –Increases the design space Material Extrusion Powder Bed Fusion Directed Energy

7. 7 Background: Potential Benefits 1 st : Affordability –Reduce tooling, waste –Complexity = Simplicity 2 nd : Smart(er) Manufacturing –Integrate processes –Support RP & production 3 rd : Optimize Product Design –Reduce weight, support modularity –Multi-functional parts Traditionally: 9 piece welded duct assembly AM: 2-piece bonded assembly With Additive You Can Design for Functionality Oak Ridge National Lab F-35 Representative Parts

8. Agenda Introduction Technology Background Applications –Snap Shot –Industrial Examples –Industrial Diversity Paths-Forward NAMII Summary & Conclusion 8

9. Applications: Snap Shot Polymeric Components –Laser Sintering (LS) Certified and flying (Comm. & Def.) FDA 510(k)-approved –Hybrid Applications with Direct Write & Extrusions Embedded sensors / continuous fiber Metallic Components –Laser and Electron Beam Melting Implants, replacements Aerospace components Creates Difficult to Machine Shapes Provides Similar Mechanical Properties (NGC) Enables Hybrid Uses 9 Improves Performance (Courtesy EOS & WITHIN)

10. Applications: Industrial Examples 10 Composite Interface Fitting (JWST) Traditional ManufacturingAdditive Manufacturing ~500 CNC machining hours32 build hours ~16 – 26 week lead time~4 day lead time Nominal60% - 70% cost savings ~10” (25.4cm) As-Fabricated ~8” (20.3cm) Post Machining and NDI Hot Air Mixer (UCAS-D) Traditional ManufacturingAdditive Manufacturing Buy-to-Fly ratio 10 – 20:1Buy-to-Fly ratio ~2:1 Min. 4-pieces w/ 2 welds1 piece w/ no welding Nominal35% - 45% cost savings Courtesy of Northrop Grumman Corp. and CalRam Inc.

11. Applications: Industrial Diversity Additive Manufacturing: An Enabler for Next-Gen Production Functional Furniture Large Structures Antennae Sensors Multi-Functional Parts Functional Apparel Toys & Model Hobbyists Weight Reductions Complex Parts 11 Traditional Machined Casting Additive Selectively Builds

12. Agenda Introduction Technology Background Applications Paths-Forward –Research Potential –Business Potential NAMII Summary & Conclusion 12

13. Paths-Forward: Research Potential Processing –Thermal control –In situ sensor feedback –Melt pool dynamics Materials –Increased functionality –AM-specific formulation –Nano-materials Model-Based Enterprise –Physics-based simulation –Enabling digital thread –Improved design tools 13 http://www.sti-tech.com/fea.html Nylon CNF with Poor Dispersion Courtesy of Paramount Industries Courtesy of EOS

14. Paths-Forward: Business Potential Source – http://wohlersassociates.com 14 Trending From Prototyping-Only To Now Include Production PRODUCTS: Direct Part Manufacturing (19.2%) Functional Models (18.4%) MARKETS: Consumer & Auto ~40% Aero & Medical / Dental Accelerating Wohler’s Associates site to order “Wohlers Report”

15. Agenda Introduction Background Applications Paths-Forward NAMII Summary & Conclusion 15

16. A DMS&T team-led, Multi-agency collaboration between industry, government and universities Public-private partnership A DMS&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 Bridge the gap in Manufacturing Innovation –Workforce Development (K-to-Gray) Industrial Commons for Collaborative Innovation Focused on Advancing AM Industry

17. NAMII: 1 st Project Awards Maturation of Fused Depositing Modeling (FDM) Component Manufacturing” – Rapid Prototype + Manufacturing LLC (RP+M) “Qualification of Additive Manufacturing Processes and Procedures for Repurposing and Rejuvenation of Tooling” – Case Western Reserve University Sparse-Build Rapid Tooling by Fused Depositing Modeling (FDM) for Composite Manufacturing and Hydroforming” – Missouri University of Science and Technology “Fused Depositing Modeling (FDM) for Complex Composites Tooling” – Northrop Grumman Aerospace Systems “Maturation of High-Temperature Selective Laser Sintering (SLS) Technologies and Infrastructure” – Northrop Grumman Aerospace Systems “Thermal Imaging for Process Monitoring and Control of Additive Manufacturing” – Penn State University Center for Innovative Materials Processing through Direct Digital Deposition (CIMP 3D) “Rapid Qualification Methods for Powder Bed Direct Metal Additive Manufacturing Processes” – Case Western Reserve University 17

18. Agenda Introduction Background Applications Paths-Forward NAMII Summary & Conclusion 18

19. The Technology –Not just a maker movement –Enables design for functionality –Key piece in digital enterprise (MBE, AME) The Application –Need: Increased processing understanding –Supports prototyping, functional models, end-use –AM discriminator: Knowing how to use AM Summary & Conclusion Additive Is A Compliment to Current Manufacturing 19

20. Tim Shinbara Technical Director, AMT tshinbara@AMTonline.org 703.827.5243 (desk) Contact Information Questions? 20