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YOUNGSTOWN, OHIO – The National Center for Defense Manufacturing and Machining (NCDMM) and America Makes are proud to announce the winners of the “Improvements in Manufacturing Productivity via Additive Capabilities and Techno-Economic Analysis (IMPACT)” directed project call funded by the Office of the Under Secretary of Defense, Research and Engineering Manufacturing Technology Office (OSD(R&E)) and the Air Force Research Laboratory (AFRL), worth a total of $11.7M.
The objective of the IMPACT project call is to demonstrate productivity and yield benefits for casting and forging manufacturing via additive manufacturing (AM) technologies, execute techno-economic analysis for metal powder AM, and to bridge component sourcing gaps with AM parts for casting and forging applications. Additionally, the project call was seeking innovative solutions in robotic AM process planning for continuous fiber-reinforced composite structures.
AM is of significant interest to the U.S. manufacturing base as the technology enables shorter lead times, mass customization, energy reduction, complex shapes, and production of parts on demand providing benefits to both new acquisitions and legacy systems. “This project call addresses the needs of a broad cross-section of our nation’s supply chain including the casting and forging industry,” stated Brandon Ribic, Ph.D., America Makes Technology Director. “The U.S. government considers metal casting and forgings to be one of the most critical supply chain items to our national defense and economic health. Thus, we see the need for casting and forging operations to seek advanced manufacturing capabilities that can upgrade production capacity, improve throughput, reduce cost, and take risks out of the supply chain equation. The awardees of this project call will work to shed light on the critical need for long-term strategic investments in AM to strengthen the U.S. supply chain.”
Additionally, the techno-economic analysis study on metal powder AM seeks to prioritize investment areas to improve the business case of one of the most mature AM processes. The research in robotic planning strategies for continuous fiber-reinforced printing aims at reducing the producibility barriers of autonomous unmanned aerial vehicles. “Applying the full 3-dimensional power of advanced manufacturing technologies, such as industrial robotic arms to use for AM applications can unlock many unseen potentials,” stated John Martin, America Makes Additive Manufacturing Research Director.
Below is the list of award winners and related topics/projects:
Topic 1: Develop/disseminate leading practices and accelerate the adoption of 3D printed molds/cores for sand castings
Topic 2: Mature AM ceramic technology and promote adoption for rapid, low-volume production of investment castings for defense applications
Topic 5: Optimizing Forging Preforms Production Using Different Additive Manufacturing Routes: Process Selection, Testing, and Performance Evaluation
Topic 6: Develop and disseminate leading DED and cold spray practices to promote adoption of die repair for forging applications
Topic 8: Techno-economic analysis and manufacturing readiness assessments to address bridging component sourcing gaps with AM parts for critical casting and forging production
Topic 9: Powder AM techno-economic analysis
Topic 10: Innovations in robotic additive manufacturing process planning
Project teams will report on their progress with these projects at the America Makes Technical Review and Exchange and other industry events during the execution phase of the program.