5541 Team Red: Thorough Evaluation of AM with Rigorous Expertise and Data

Team Red Organization and Interactions with the Delta Qual Program


Additive manufacturing (AM) machines and materials qualification are major barriers to broad AM adoption. Generating the requisite data and models requires significant resources to produce statistically significant data. This qualification process requires generating test coupons under a controlled process and testing and analysis of the resulting data. These processes are then “frozen” with no changes to key process variables allowed. Standard-based guidance does not exist for requirements when a process change is needed. This greatly inhibits the agility of AM processes to respond to changes in the technology or supply base, allowing only one path to implement change to a qualified process — a total requalification, which may cost more than $3M per machine/material combination and take several years.


This project will demonstrate the ability to rapidly and affordably update and/or establish a qualified AM process that can allow for changes in key AM process, post-processing, and/or material feedstock variables.

Technical Approach

Under this project, Team Red, The Barnes Global Advisors (TBGA) will research, map, document, and analyze AM qualification approaches, including relevant material/process specifications, and develop a conservative (nearly start from scratch) baseline for comparison. The team will review and evaluate the demonstration projects, identify both positive and negative lessons learned, and rate them against the key performance parameters (KPPs), and the baseline test matrix and plan. Following the evaluation activities, Team Red will complete its analyses and document its final recommendations. Any recommendations will be communicated to the America Makes Technology Roadmaps team for consideration in future activities.

Project Participants

Project Principal

Other Project Participants

  • BlueForge Alliance
  • Carnegie-Mellon University
  • Federal Aviation Administration
  • NASA
  • Sandia National Laboratories
  • SAE International

Public Participants

  • U.S. Department of Defense

Project Summary

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