AM offers numerous opportunities to improve the DoD maintenance enterprise’s ability to deliver weapon systems faster and in some cases with improved designs. Some of AMs greatest benefits include time, cost, complexity, and customization, compared to some its greatest challenges in quality, trust in meeting requirements, and workforce development. OSD and the military services are investing substantial resources to advance AM technologies, processes, and material to improve DoD sustainment operations. These efforts include the development of Military Service AM implementation plans, establishment of joint leadership and working groups, and qualification and certification of AM repairs and parts production.
Currently, AM in DoD is primarily decentralized within the military services, with a goal for selective AM capabilities to be developed in a centralized manner to qualify noncritical parts. This will allow the standardization of AM equipment, processes, and training to be shared and implemented across the DoD enterprise. Once obtained, a “global AM network” can be established to include a cyber-secure parts library.
This forum will examine ongoing efforts to implement AM across the DoD sustainment enterprise, including a discussion on DoD AM policy and guidance, a description of the Joint Additive Manufacturing Working Group (JAMWG) and their goals for 2020, and updates from the Military Services on their AM implementation plans and the AM capabilities they are currently implementing and developing.
The Additive Manufacturing forum will be conducted virtually via Adobe Connect and an audio line. The link and audio information are below.
1300-1309: Welcome – Greg Kilchenstein (OSD-MR) Presentation
1309-1310: Administrative Notes – Debbie Lilu (NCMS)
1310-1330: Additive Manufacturing Policy Update – Greg Kilchenstein (OSD-MR) & Kelly Visconti (OSD-RE) Presentation
1330-1350: Joint Additive Manufacturing Working Group (JAMWG) – Kelly Visconti (OSD-RE)Presentation
1350-1420: NAVAIR AM Update – Liz McMichael / Alan Pentz (NAVAIR) Presentation
1420-1440: NAVSEA AM Update – Dr. Justin Rettaliata (NAVSEA) Presentation
1440-1455: Army AM Update – Dr. Bernard Goodly (HQ, AMC)
1455-1500: Wrap-Up Presentation
Event: On 31 March 2020, the Joint Technology Exchange Group (JTEG), in coordination with the National Center for Manufacturing Sciences (NCMS), hosted a virtual forum on “Additive Manufacturing in Support of DoD Maintenance”.
Purpose: The purpose of this forum was to examine ongoing efforts to implement AM across the DoD sustainment enterprise, including a discussion on DoD AM policy and guidance, a description of the Joint Additive Manufacturing Working Group (JAMWG) and their goals for 2020, and updates from the Military Services on their AM implementation plans and the AM capabilities they are currently implementing and developing. Additionally, a description and update on the COVID-19 Joint Acquisition Task Force (JATF) was provided.
Welcome: Greg Kilchenstein (OSD-MR) welcomed everyone to the forum and thanked the presenters and all the listeners for their attendance. He also stated how important additive manufacturing capabilities are to assist with the current response to the COVID-19 crisis, as well as improving efficiency and effectiveness within the DoD maintenance community.
Administrative: This was an open forum. The presentations, along with questions and answers, were conducted through Adobe Connect and Zoom, and several briefs were available online at the JTEG website at http://jteg.ncms.org/. A separate audio line was used. We had 148 participants from across DOD, industry, and academia join in the forum.
COVID-19 JATF Update – Greg Kilchenstein (OSD-MR) stated that DoD has established a joint task force to deal with daily requests the department is receiving for medical and personal protective equipment (PPE) from the Federal Emergency Management Agency (FEMA), the departments of Health and Human Services and Homeland Security, and others. The JATF was working on identifying ways to use DoD rapid manufacturing capabilities to help fill shortfalls within the industrial base. They have received a “Wishlist” from the CDC and are collecting information on known activities using AM and related information to support the COVID19 response and coordinating information across the DoD. They are setting up a data collection portal to collect all the databases on supply availability/capacity. NCMS has put a call in to their manufacturing base, and the USAF is collecting information through AFWERX.
Supplies and equipment that the JATF is focusing on include:
- Face shields and face masks
- COVID-19 Assessment capabilities
- Capabilities to mass sterilize equipment or PPE
Army AM Update – Dr Bernard Goodly (HQ, AMC) stated that his office is also heavily involved in supporting the COVID-19 response effort. He stated that the focus of the AM Campaign is on readiness drivers, and in the development of the digital thread to link AM into Army Enterprise Resource Planning. Rock Island Arsenal Joint Manufacturing Technology is the AM Center of Excellence. Dr Goodly stressed the importance of workforce training, public private partnerships, and candidate parts assessment, certification, and qualification.
AM Policy Update – Greg Kilchenstein (OSD-MR) & Kelly Visconti (OSD-RE) stated that the draft DoDI titled “Use of Additive Manufacturing in the DoD” has completed informal coordination through OSD and is in the process of being submitted for formal coordination.
Additive Manufacturing Workshop 2020 – The workshop is still on for 23-24 June in Crystal City, VA. Workshop overview, abstracts of the 9 working groups, and registration are all available on the AMMO website at https://ammo.ncms.org/events/2020-additive-manufacturing-workshop/ .
Joint Additive Manufacturing Working Group (JAMWG) – Kelly Visconti (OSD-RE) discussed DoD AM strategy and the role of the OUSD R&E). She then described the JAMWG objectives to include: Joint AM investment strategy, DoD AM vision, disseminate information, and promote joint qualification approaches. The JAMWG is organized into four business councils:
- Data and Model Sharing
- Qualification and Certification
- Education and Workforce Development
- Business Practices
Kelly also discussed a couple OUSD R&E funded JAMWG projects: Digital Thread and Rapid Qualification, before expanding on JAMWG FY20-21 priorities which include accelerating qualification and certification of AM materials machines, and parts; enhancing a secure common digital thread across DoD and industry; expanding proficiency in AM; develop DoD and supply chain integration policies and guidance; and improve communication effectiveness on AM. She closed by explaining OUSD R&E’s three approaches: lead and facilitate, partner, and invest in R&D to support modernization, material readiness, and warfighter capability.
NAVAIR AM Update – Alan Pentz (NAVAIR) described NAVAIR’s approach of “Mainstreaming” AM for Naval aviation with the goals to “Maximize the use of AM to fabricate hard-to-source or obsolete parts, reduce cost, field more effective systems and reduce reliance on vulnerable supply chains through production at the point of need” – CNO Design 2.0, and develop and deliver the means to design, certify, produce, and use AM components across the life cycle of aviation platforms and systems. He described a few demonstrations and validations to include maturing metal AM qual/cert, validation processes of successful redesigns of components to be printed, rapid response examples, and AM integration into NAVAIR’s digital transformation.
NAVSEA AM Update – Dr. Justin Rettaliata (NAVSEA) described some of NACSEA’s key initiatives to include developing specifications and standards necessary to incorporate
AM components for surface and subsurface applications, engaging fleet and leverage logistics databases to ID priority components, prototyping the digital infrastructure to securely store and share files, publishing policy for installing equipment onboard submarines, and working closely with industry on identification and approval of components for AM. He discussed the NAVSEA AM approval process and specification/standard development, to include “Who has the authority to approve AM parts?” He stated the need to integrate with the supply chain and the goal to develop Data-driven AM part identification using automated logistics, supply and maintenance
Data. He finished by describing afloat/expeditionary AM to include ship modifications, equipment installation and networking challenges.
Q&A – A Q&A occurred after each briefer finished their presentation. Questions and answers will be posted on the JTEG website with these minutes.
Closing Comments: Greg Kilchenstein thanked the presenters for their contributions and all the work being done to support additive manufacturing capabilities efforts across DoD sustainment. He suggested continuing the information exchange beyond the forum and the importance of collaboration within the DoD maintenance community.
- All cleared briefing slides were posted to the JTEG website at http://jteg.ncms.org/ prior to the forum start.
Next JTEG Meeting: The next scheduled JTEG virtual forum is 28 April 2020, 1:00 – 3:00 pm EST. The topic is “Cold Spray Repair”.
POC this action is Ray Langlais, firstname.lastname@example.org, (571) 633-8019
Army AM Update – (Dr Bernard Goodly)
Q1. Can you discuss how Rock Island was able to obtain an ATO to connect their 3-D printers to the network in a cyber-secure manner?
A1. I don’t know if we have received an ATO. It is a very structured process.
Q2. for Dr. Meyer – does the Army Med R&D Command have a streamlined process to get AM manufactured medical supplies evaluated and approved rapidly?
A2. It depends on the item. In general, manufacturing is responsible for doing all the testing. Under the current circumstances, some are waived depending on the item and the risk.
Q3. Does the army have an AM military occupational specialty (MOS)?
A3. Not a specific MOS. 91E and 914 are the MOS that work in the metalworker shops.
Q4. What printer are you using in these Army Shelters? and What material are you using?
A4. We have C&C milling machines, lathes, polymer part printer, Miller arc welder, tig welder, and a cutting machine.
AM Policy & AM Workshop Updates: Greg Kilchenstein (OSD(MR)
Q1. How does digital thread factor into these working groups?
A1. Very much. Technical data package is the digital rendering, Cybersecurity is a challenge.
Q2. Where is the DoD-level AM Guidebook in the drafting/review process?
A2. Infant stages. We are still trying to get the AM DoDI approved. I don’t want to get too far ahead of the DoDI.
Q3. Greg will things like how AM enabled tooling speeds manufacturing of castings, etc. be considered in the AM Metrics working group?
A3. Yes. We, for example we have additive sand-casting machines.
Q4. Are there contingencies in place in the event that the country is still in a shelter-in-place mode at the time of the conference?
A4. Not at this point. We have had conversations on the topic, but it would be difficult to do virtually. We would more likely reschedule before doing it virtually.
Q5. Will we be mapping part criticality to requirements? More specifically material property requirements?
A5. Yes, I think that we have to.
JAMWG: Kelly Visconti (OSD-RE)
Q1. Does the common technical data package standard define a digital/machine-readable format for a package?
A1. I do not know the specifics of how to do that. I will find out.
NAVAIR AM Update: Alan Pentz
Q1. Is NAVAIR planning on using JAMMEX as their digital thread/digital platform? If not, how do the Navy’s solution and JAMMEX relate/interact in the digital ecosystem?
A1. Part of it. We didn’t want a lot of files sitting in the repository. Files are dynamic. We want a general portal to connect to. We may even time out some of the data.
Q2. How are cybersecurity and AM machine ATO handled in the “distributed printing” program mentioned on slide 8?
A2. We have used our cyber folks to test and connect. One of the challenges is that we have a lot of types of machines.
Q3. On slide 8, “Where are we?” are the totals in the bar chart “eaches” or distinctly different items?
A3. Left side – distinct items
Q4. What percentage of AM qualified parts are metal parts?
A4. About 5% are metal parts.
NAVSEA AM Update – Dr. Justin Rettaliata (NAVSEA)
Q1. What machines were put onboard ships (metal or polymer)? and what other concerns were considered (material storage, safety, etc.)
A1. Polymer. One concern was to be smart in selecting what to print. Ensure it is applicable and within the capability.
Q2. Any plan for metallic AM printers onboard ship?
A2. We are looking into it as part of our FY 2021 efforts. We are going through down select and haven’t selected which ones yet.