1. Quality Metal Additive Manufacturing (QUALITY MADE)
Call for Teaming
Rob Gorham
America Makes
Director of Operations

2. Call for Teaming Logistics ONR Information
NCDMM Intends to Prime a Response to the Broad Agency Announcement (BAA)
NCDMM BAA Response to Integrate America Makes as Core
Capture Manager: Rob Gorham
ACTION: Teaming Interest due to by September 11 (see last slide)
ONR Information
BAA Announcement Expected October 2015
Program Start Expected October 2016
Duration: 4 Years, FY17-20

3. Why America Makes Win Strategies
Leverage the America Makes Mission (Process, Org, Network)
Leverage Current Funded Projects Driven Aligned to the America Makes Membership Led Roadmap v2.0
Leverage the Growing Membership Strength and Diversity
Leverage the Intellectual Property Model for Transition

4. QUALITY MADE Program Goals

5. QUALITY MADE Program Goals

6. QUALITY MADE Program Goals
Digital Design Tools
Integrated Computational Materials Engineering
Qualification and Certification
Sensors / Closed Loop Feedback Control

7. Roadmap v2.0 Update – Level 1 resented at Fall 2014 PMR)
2015
2016
2017
2018
Design
Bio-Inspired Design & Manufacturing (2 Ideas)
Product & Process Design Aides/Apps (12 Ideas)
Cost & Energy Driver Analysis/Modeling (5 Ideas)
Material
“Non Ad-Hoc” Additive Manufacturing Tech Data Packages (7 Ideas)
Material Property Characterization (10 Ideas)
Next-Gen Materials (6 Ideas)
Process
Multi-Material Delivery & Deposition Systems (3 Ideas)
Next-Gen Machines (8 Ideas)
Process Temp Gradient Control (2 Ideas)
Standards/Schemas/Protocols (10 Ideas)
Rapid Inspection Technologies (1 Idea)
Value Chain
Advanced Sensing and Detection Methods (5 Ideas)
Repair Technologies (1 Idea)
Intelligent Machine Control Methods (4 Ideas)
Digital Thread Integration (4 Ideas)
AM Genome
Benchmark Validation Use Cases (3 Ideas)
Physics-Based Modeling & Simulation (5 Ideas)
Model Assisted Property Prediction (2 Idea)

8. Roadmap v2.0 Update – Level 2
Design Level 2 Roadmap
Maturation Needs
2013
2014
2015
2016
2017
2018
2019
2020
Bio-Inspired Design & Manufacturing (2 Ideas)
Cellular FEA Topology Models for DMLS Ti-64 ( )
Efficient Structural Analysis Algorithms for Cellular Structures (v1.0)
Cost & Energy Driver Analysis/Modeling (5 Ideas)
Ti-64 DMLS Production Cost Modeling ( )
Ti-64 EBM Production Cost Modeling ( )
Cradle-to-Cradle Life Cycle Energy Use Modeling (v1.0)
Product/Process Family Energy Use Modeling (v1.0)
Product & Process Design Aides/Apps (14 Ideas)
FDM ULTEM 9085 Tooling Design Guidelines ( )
SLS CFR ESD PEKK Topology Optimization Guidelines ( )
Integrated AM and Secondary Machining Support Guidelines ( )
FDM ULTEM 9085 Part Design and Build Path Guidelines ( )
Design for Additive Manufacturing Criteria and Analysis Tools (PC 3)
CFR Polymer CAD/CAM/CAE Optimization Tools (PC 3)
Material-Process Selection Design Advisors (PC 3)
Additive Manufacturing vs. Conventional Process Trade-Off Criteria (PC 3)
Process Map Based Machine Set-Up and Programming (PC 3)
CAD Linkable Expert Design Advisors (v1.0)
Rule-Based DFM Methods & Algorithms (v1.0)
Design Specification Query Algorithms (v1.0)
Automatic Generation of Process/Material/Machine Compliance Matrices (v1.0)
Design Advisors that Recommend Rapid Qual/Cert Approaches (v1.0)

9. Roadmap v2.0 Update – Level 2
Materials Level 2 Roadmap
Maturation Needs
2013
2014
2015
2016
2017
2018
2019
2020
“Non Ad Hoc” Additive Manufacturing Tech Data Packages (8 Ideas)
EBM Ti-64 & Co-Cr PV Process Maps ( )
DMLS Ti-64 & Co-Cr PV Process Maps ( )
LENS Ti-64 & IN718 Process Window Characterization ( )
EB-DED Ti-64 Microstructure for Ultrasonic NDI ( )
Metallic Alloy Process Variable to Process Outcome Maps (PC 3)
Non-Metal Process Variable to Process Outcome Mapping (PC 3)
Process Specific Defect & Instability Boundary Mapping (PC 3)
Post-Processing Guidelines for Microstructure Optimization (PC 3)
Material Property Characterization (12 Ideas)
FDM ULTEM 9085 B-Basis Allowable Data ( )
SLS CFR ESD PEKK B-Basis Design Allowable Data ( )
Conductive Ink-Ceramic Material Compatibility/Adhesion (PC 3)
SLS PEKK Characterization ( )
Standardized Feedstock Specifications for Tungsten Alloys (PC 3)
SLS Cu Characterization ( )
"As-Built" Tungsten Alloy Material Property Characterization (PC 3)
EBM Ti-64 & Co-Cr Feedstock to Property Relationships ( )
DMLS Ti-64 & Co-Cr Feedstock to Property Relationships ( )
EBM Ti-64 & Co-Cr Wire Feedstock Effects on Microstructure ( )
DMLS Ti-64 & Co-Cr Powder Feedstock Effects on Microstructure ( )
EBM Ti-64 B-Basis Allowable Development ( )
Next-Gen Materials (10 Ideas)
SLS CFR ESD PEKK Recyclability Guidelines ( )
High-Temp Fireable Conductive Inks for Ceramic Substrates (PC 3)
Material Recyclability Indices (v1.0)
Conductive Ink Rheology Optimization for improved Adhesion (PC 3)
High-Flowability Low-Temp Ink Rheologies for High AR Vias (PC 3)
Harsh Environment High Durability Conductive Ink Chemistries (PC 3)
High Melting Point Tungsten Alloy Development (PC 3)
Low Cost Recycled Al Material Specifications ( )
Forging Tool Wear Resistant Coating Guidelines ( )
Biocompatible/Bioabsorbable Binder-Jet Fe-Mn ( )

10. Roadmap v2.0 Update – Level 2
Process Level 2 Roadmap
Maturation Needs
2013
2014
2015
2016
2017
2018
2019
2020
Multi-Material Delivery & Deposition (2 Ideas)
Adaptable Chemistry Conductive Ink Print Heads (PC 3)
3D-Gradient Material Deposition Control (v1.0)
Next-Gen Machines (9 Ideas)
Modular LENS Machine Tool Retrofit Systems ( )
Open Source PLC Architectures (v1.0)
Low Cost Recycled Aluminum Desktop Printer ( )
Micro-Induction Sintering Test Bed ( )
High-Throughput LHW Ni & Ti Processing ( )
Hybrid AM and Subtractive Systems ( )
90 Deg Bend Conductive Ink Nozzle Optimization (PC 3)
Conductive Ink Printing for 3D High AR Structures (PC 3)
5mm Line/Trace Resolution Ink Printing Machines (PC 3)
Process Temperature Gradient Control Systems (2 Ideas)
Multi-Power Source Deposition & Thermal Management Systems (PC 3)
Real-Time Processing Temperature Analysis Methodologies (v1.0)

11. Roadmap v2.0 Update – Level 2
Value Chain Level 2 Roadmap
Maturation Needs
2013
2014
2015
2016
2017
2018
2019
2020
Advanced Sensing & Detection Methods (6 Ideas)
Multi-Sensor Thermal Imaging Systems for EBM & LENS Processes ( )
3D Visualization Methods for Thermal Imaging Data ( )
In-Situ Laser PBF Defect Monitoring Sensor Test Bed ( EWI)
IR Imaging for Laser PBF Thermoplastics ( )
High Accuracy Fast Response Quality Sensing (PC 3)
3D Melt Pool Temp Distribution Measurements (PC 3)
Digital Thread Integration (2 Ideas)
MBE Methods for Integrated AM & Secondary Machining ( )
Real-Time "As-Designed" vs. "As-Built" Tolerance Comparisons (v1.0)
Intelligent Machine Control Methods (6 Ideas)
Process Map Microstructure Control Algorithms ( )
Real-Time In-Situ Defect Rework Control Algorithms (PC 3)
Distortion Compensation Control Algorithms ( )
Model-Based Closed Loop Feedback Control Algorithms (v1.0)
Integrated AM & Secondary Machining Control ( )
Thermal Imaging Control of Laser PBF Thermoplastics ( )
Rapid Inspection Technologies (5 Ideas)
Layer-by-Layer 3D Quality Certificates ( UofL)
In-Situ QA Methods for Superalloy Laser PBF ( )
NDE Post-Build Inspection of Laser PBF ( CTC)
Ti & Ni Alloy X-Ray CT NDI Procedures ( )
3D Visualization Tools for Real-Time QA Monitoring (PC 3)
Repair Technologies (2 Ideas)
H13 Die Cast Tooling Repair & Rejuvenation Guidelines ( )
Laser Powder Directed Energy Part Repair Methods ( )
Standards/Schemas/Protocols (11 Ideas)
NIST Round Robin Protocols (5 Standards)
Open Laser PBF Control Protocols ( )
Industry Specific Qual/Cert Protocols (v1.0)
EB-DED Ti-64 Ultrasonic NDI Protocols ( )
Third Party Data Capture Templates (v1.0)
Data Repository Card Catalog & Pedigrees (v1.0)
Shared Data Repository Schemas (v1.0)

12. Roadmap v2.0 Update – Level 2
AM Genome Level 2 Roadmap
Maturation Needs
2013
2014
2015
2016
2017
2018
2019
2020
Benchmark Validation Use Cases (4 Ideas)
EB-DED Ti-64 Ultrasonic NDI Test Coupons ( )
Ti & Ni Alloy X-Ray CT NDI Reference Test Coupons ( )
Reference NDI Test Coupons for Microstructure Control (PC 3)
Experimental Metallic Alloy Melt Pool & Distortion Data (PC 3)
Model-Assisted Property Prediction (2 Ideas)
CFR ULTEM Reduced Order Property Prediction Tools (PC 3)
ICME & Data Repository Statistical Model Links (v1.0)
Physics-Based Modeling & Simulation (8 Ideas)
EBM Al Process Modeling ( )
Laser PBF Al Process Modeling ( )
DMLS Numerical Simulation Methods ( )
LENS Ti-64 ABAQUS FEA Set-Up Scripts ( )
Laser PBF Ni, Co, and Ti Distortion Modeling ( )
Laser PBF Ni, Ti, Co-Cr Melt Pool & Solidification Modeling (PC 3)
Tungsten Melt Pool, Solidification, & Distortion Modeling (PC 3)
M&S Tools for FDM Chopped Fiber Orientation Prediction (PC 3)

13. Next Steps
America Makes Teaming Interest
Indicate your interest in participating in an America Makes Proposal Team
Recommend potential participants (members and/or non-member)
Current Capabilities and Relevant Work
Indicate current capability aligned to ONR QUALITY MADE Program Objectives
Indicate current projects (America Makes or Non-America Makes) aligned to ONR QUALITY MADE Program Objectives
Submit Responses to Rob Gorham by Friday, September 11, 2015

14. When America Makes America Works
AmericaMakes.us
@AmericaMakes