Portfolio Status: Completed Projects

5001.002.002.001 Hybrid Additive Manufacturing Error Recognition and Resolution (HAMERR)

January 26, 2024

The team sought to develop a system to identify and correct geometric non-conformities during the build process of a powder-fed DED printer with machining capabilities. This system would monitor...

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5528.001 AURA TrustedAM™ Mark I Endpoint Assessment Activity

January 25, 2024

The goal of the project was to provide a means for AM machines in the DoD to connect to an IT system using an encrypted secure digital device without having to qualify or certify via ATO/RMF (risk...

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5001.003.002.003 Measurement of Process Gas Flow and Delivered Laser Powder Impact Toward AM Machine Qualification

December 18, 2023

Characterize the impact of gas flow and differences in delivered laser power on the mechanical properties of Ti-6Al-4V components produced by laser powder bed fusion (PBF-LB)...

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5513.001 Thermal Aging Study for Additively Manufactured F357 Aluminum

December 18, 2023

The objective of this program was to enable the use of aluminum alloys for high-temperature applications by understanding the effects of thermal treatments and service temperatures on the...

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5001.004.001.001 Frameworks for Utilizing Process Monitoring in Conjunction with Ex-situ Inspection for Qualification

November 27, 2023

The goal of the project was to foster conditional inspection practices by evaluating different in-situ monitoring framework qualities and features for their ability to predict post-build...

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5001.003.001.004 Characterization of Transient Phenomena Impacting In-Situ Molten Pool Temperature Measurement for AM of Reactive Metals

October 11, 2023

The objectives of this project were to demonstrate a method to measure the melt pool emission spectra routinely, accurately, and in near-real-time during LPBF processing of reactive metals (e.g.,...

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5001.002.001.001 Qualification of Additive Aluminum Alloys for High-Temperature Extreme Environments (QUAAL-HT)

October 10, 2023

The primary objectives for this project were to mature an aluminum alloy to meet performance targets for elevated temperature applications and demonstrate candidate alloy in representative part...

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5548 Craitor Expeditionary 3D Printer

September 18, 2023

This project aimed to optimize the design of Craitor’s 3D printer based on testing to the requirements of MIL-STD-810G and demonstrated its performance in cold weather, high temperature, and...

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5551 Cold Metal Fusion Preliminary Research for Air Force Sustainment and Repair

September 07, 2023

The project objective was to develop and demonstrate a cold metal fusion printing process through manufacturing and testing Ti6AI4V specimens. The team created three manufacturing builds to verify...

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5515.001 USN Submarine Propulsor Application: ULTEM 9085 Production Specification and Support

August 30, 2023

The objective of the project was to create functional COLUMBIA (CLB) Class Submarine Propulsor components that can perform under the intended application and benefit from the advantages of the...

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5001.003.001.001 Surface Finish Design Guide for Additive Manufacturing (AM) Heat Exchangers

August 29, 2023

The purpose of the project was to develop a design guide for additive manufactured (AM) heat exchangers with complex internal geometries that incorporated surface roughness correction factors for...

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5001.003.001.003 AM Materials Safety Training

August 28, 2023

The objective of this work was to create and deliver training materials that facilitated the quick training of existing and future experts on the lifecycle of AM...

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