America Makes Technology Roadmap v 2.0

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1 America Makes Technology Roadmap v 2.0 John Wilczynski America Makes Deputy Director Technology Development

2 America Makes Technology Roadmap Level 1resented at Fall 2014 Gray PMR) Space with < 5 CTE Maturation Ideas Design Product & Process Design Aides/Apps Cost & Energy Driver Analysis/Modeling Bio-Inspired Design & Manufacturing Material Material Property Characterization Non Ad-Hoc Additive Manufacturing Tech Data Packages Next-Gen Materials Process Next-Gen Machines Multi-Material Delivery & Deposition Systems Process Temp Gradient Control Value Chain AM Genome Standards/Schemas/Protocols Rapid Inspection Technologies Advanced Sensing and Detection Methods Repair Technologies Intelligent Machine Control Methods Digital Thread Integration Benchmark Validation Use Cases Physics-Based Modeling & Simulation Model Assisted Property Prediction

3 Ti-64 DMLS Production Cost Modeling Ti-64 EBM Production Cost Modeling FDM ULTEM 9085 Tooling Design Guidelines Cellular FEA Topology Models for DMLS Ti-64 SLS CFR ESD PEKK Topology Optimization Guidelines Integrated AM and Secondary Machining Support Guidelines FDM ULTEM 9085 Part Design and Build Path Guidelines Bio-Inspired Design & Manufacturing Cost & Energy Driver Analysis/Modeling Product & Process Design Aides/Apps DESIGN Level Efficient Structural Analysis Algorithms for Cellular Structures Cradle-to-Cradle Life Cycle Energy Use Modeling Product/Process Family Energy Use Modeling CAD Linkable Expert Design Advisors Rule-Based DFM Methods & Algorithms Design Specification Query Algorithms Automatic Generation of Process/Material/Machine Compliance Design Advisors that Recommend Rapid Qual/Cert Approaches

4 EBM Ti-64 & Co-Cr PV Process Maps DMLS Ti-64 & Co-Cr PV Process Maps LENS Ti-64 & IN718 Process Window Characterization EB-DED Ti-64 Microstructure for Ultrasonic NDI Non Ad Hoc Additive Manufacturing Tech Data Packages MATERIAL Material Property Characterization FDM ULTEM 9085 B-Basis Allowable Data SLS CFR ESD PEKK B-Basis Design Allowable Data SLS PEKK Characterization SLS Cu Characterization EBM Ti-64 & Co-Cr Feedstock to Property Relationships DMLS Ti-64 & Co-Cr Feedstock to Property Relationships EBM Ti-64 & Co-Cr Wire Feedstock Effects on Microstructure DMLS Ti-64 & Co-Cr Powder Feedstock Effects on Microstructure EBM Ti-64 B-Basis Allowable Development Next-Gen Materials SLS CFR ESD PEKK Recyclability Guidelines Low Cost Recycled Al Material Specifications Forging Tool Wear Resistant Coating Guidelines Biocompatible/Bioabsorbable Binder-Jet Fe-Mn Material Recyclability Indices

5 Modular LENS Machine Tool Retrofit Systems Low Cost Recycled Aluminum Desktop Printer Micro-Induction Sintering Test Bed High-Throughput LHW Ni & Ti Processing Hybrid AM and Subtractive Systems Multi-Material Delivery & Deposition Next-Gen Machines PROCESS 3D-Gradient Material Deposition Control Open Source PLC Architectures Process Temperature Gradient Control Systems Real-Time Processing Temperature Analysis Methodologies

6 America Makes Technology Roadmap Multi-Sensor Thermal Imaging Systems for EBM & LENS Processes 3D Visualization Methods for Thermal Imaging Data In-Situ Laser PBF Defect Monitoring Sensor Test Bed Advanced Sensing & Detection Methods IR Imaging for Laser PBF Thermoplastics VALUE CHAIN Digital Thread Integration MBE Methods for Integrated AM & Secondary Machining Real-Time "As-Designed" vs. "As-Built" Toler. Comparisons Intelligent Machine Control Methods Process Map Microstructure Control Algorithms Distortion Compensation Control Algorithms Model-Based Closed Loop Feedback Control Algorithms Integrated AM & Secondary Machining Control Thermal Imaging Control of Laser PBF Thermoplastics Rapid Inspection Technologies Layer-by-Layer 3D Quality Certificates In-Situ QA Methods for Superalloy Laser PBF NDE Post-Build Inspection of Laser PBF Ti & Ni Alloy X-Ray CT NDI Procedures Repair Technologies H13 Die Cast Tooling Repair & Rejuvenation Guidelines Laser Powder Directed Energy Part Repair Methods Standards/Schemas/Protocols NIST Round Robin Protocols Open Laser PBF Control Protocols Industry Specific Qual/Cert Protocols EB-DED Ti-64 Ultrasonic NDI Protocols Third Party Data Capture Templates Data Repository Card Catalog & Pedigrees Shared Data Repository Schemas

7 EB-DED Ti-64 Ultrasonic NDI Test Coupons Benchmark Validation Use Cases Ti & Ni Alloy X-Ray CT NDI Reference Test Coupons AM GENOME Model-Assisted Property Prediction Physics-Based Modeling & Simulation EBM Al Process Modeling Laser PBF Al Process Modeling DMLS Numerical Simulation Methods LENS Ti-64 ABAQUS FEA Set-Up Scripts Laser PBF Ni, Co, and Ti Distortion Modeling ICME & Data Repository Statistical Model Links

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