1. DoD Practical Challenges
Additive Manufacturing Maintenance & Sustainment WG Face to Face Meeting
DoD Practical Challenges
Greg Kilchenstein
ODASD (Maintenance)
19 Nov 2015

2. DoD Challenge
Our Challenge: Integrate and leverage all the relevant perspectives and on-going activities into a cohesive AM strategy and tactics for the M&S community
Work collaboratively across many boundaries
Bring the M&S COI into the AM conversation
Provide a M&S focal point for the many AM stakeholder groups
M&S provide common inputs – “Speak with one voice”
Influence AM investment resource allocations for appropriate M&S COI prioritization
Keep M&S “customer” front and center in the AM revolution

3. Systems Supported by DoD Maintenance
884 strategic missiles
+ 356,385 tactical vehicles
+ Communications/electronics equipment
+ Support equipment
+ Other systems
237 ships
35,135 combat vehicles
14,444 aircraft
Maintained by:
629,000 DoD personnel
Private-sector companies
Maintenance cost:
$74.8 billion
Sustainment Cost:
$200 billion
Nearly 30% of DoD Budget

4. Current Environment Unprecedented budget pressures
Continued high OPTEMPO
Geographically dispersed operations
Older weapon systems & parts obsolescence
Very long delays for limited production parts.
Lack of commercial interest in low volume complex fabrication work and significant delays in contracting and workflow.
Organic depots are increasingly making parts to combat these challenges.
Newer weapon systems increasingly complex
Include AM parts
Rapidly evolving industrial base

5. Digital Thread/AM Challenges
AM part is currently a production lot of one
Lack of standards (materials, process, machine, and quality)
Proliferation of multiple technologies
Selective Laser Sintering (SLS) & Direct Metal Laser Sintering (DMLS)
Fused Deposition Modeling (FDM)
Stereo Lithography Apparatus (SLA)
Qualification and certification protocols
Lack of comprehensive set of design principles
Lack of manufacturing guidelines
No standard best practices
Workforce focused on traditional processes
Protecting intellectual property rights
Security and safety controls

6. What We Must Do Take control – map our future Benchmark success
Crawl, Walk, Run
Benchmark success
Develop the AM workforce – all levels
Enterprise approach to implementation
Advance our digital competency
Develop and adopt AM standards
Standardize qualification and certification
Maximize value of available resources
Partner and collaborate – its imperative!!!

7. Collaborate to Innovate
Collaborate and Join forces
AM for Maintenance Operations (AMMO) Working Group
RARE – Rapid Access to Readiness Essential Parts
America Makes M&S WG
Digital Mfg and Design Innovation Institute (DMDII)
Joint Defense Mfg Technology Panel (JDMTP)
Standards Working PSU
QUALITY MADE Initiative
Digital Engineering Working Groups - OSD(SE) & Navy
Showcases and Forums

8. AMMO WG Overview
The overarching goal of the AMMO WG is to promote the development and adoption of AM capabilities which support DoD’s maintenance mission – “Sustaining materiel readiness at best cost”
Facilitate the development of OSD guidance regarding AM technology deployment within the DoD maintenance enterprise
Facilitate the collaborative development and employment of AM technology on a continuing basis
Standardize policy and procedures
Leverage COTS technology
Capitalize on best business practices

9. AMMO WG Objectives for 2016 Improve the Way We Share Information
Monthly Forums
Win a Proposal – Execute as a Team
Standup & Use AMMO WG Website
Open Area
Working Area (Closed)
Links to other AM Sites
DoD Level AM Policy/Guidance Development
MIBP / OSD(R&E) / SE
Mil Service Components
GAO Report
Develop Content for DAU Level Courses
Continuous Learning Modules
Integrate into Logistics Acquisition Cycle

10. Monthly Forum Standard Agenda
Welcome and Overview - Greg Kilchenstein (OSD-MPP)
Old Business (Review actions, meetings, and status’ since last meeting) – Debbie Lilu
1-2 Briefs on a Selected AM or Digital Engineering Focus Area – Greg K. Intro Speakers
Service Rotation Briefs – (AMMO Principals)
AM and DE Proposal Opportunities – Debbie Lilu
Success Stories / Current Events / New Business – Debbie Lilu
 Wrap Up – Greg Kilchenstein & AMMO Principals

11. Calendar of AMMO Focus Areas
Brainstorm Possible Monthly Focus Topics
Some Suggestions:
Qualification and Certification protocols
AM Technology Descriptions
Workforce Training
Available AM Standards, Standards in Development
Protecting Intellectual Property Rights
Cybersecurity Issues
Knowledge Base Development & Data Access
Overview of AM Initiatives DoD
Organically available AM Capabilities
Additive Repair Capabilities and Successes
AM Partnerships and Partnering Best Practices