Panelist: Dr. Nabil Nasr, Director of the Golisano Institute for Sustainability, Rochester Institute of Technology, and CEO of REMADE Institute

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1 Panelist: Dr. Nabil Nasr, Director of the Golisano Institute for Sustainability, Rochester Institute of Technology, and CEO of REMADE Institute

2 OVERVIEW Nabil Nasr CEO ASA/AFR 2017 Conference JULY 10, 2017

Golisano Institute for Sustainability Over 25 Years of

Founded 2007 Center for Remanufacturing & Resource Recovery

for Sustainable Energy Systems Center for Sustainable

Research Laboratories Clean Technologies Intelligent

& Policy Sustainable Design Life Cycle Environmental and

Building Efficiency Waste to Energy Next Generation Grid

Bio-Fuels Technologies Manufacturing and End of Life of

Manufacturing Waste and Emissions Improved Efficiency in

3 Golisano Institute for Sustainability Over 25 Years of Applied Research & Industrial Applications Founded 1992 Founded 2007 Center for Remanufacturing & Resource Recovery Center of Excellence in Sustainable Manufacturing Center for Sustainable Energy Systems Center for Sustainable Mobility NYS Pollution Prevention Institute NanoPower Research Laboratories Clean Technologies Intelligent Testing & Diagnostics Design for Remanufacturing Logistics & Policy Sustainable Design Life Cycle Environmental and Economic Assessment Metrics & Policy Renewable Energy Building Efficiency Waste to Energy Next Generation Grid Smart Cities Fuel Cells Hybrid and Electric Vehicles Bio-Fuels Technologies Manufacturing and End of Life of Mobility Systems Reduction in Toxic Chemical Use Reduce Manufacturing Waste and Emissions Improved Efficiency in Raw Matls, Energy, and Water Development & characterization of nano-materials for energy conversion & storage

Manufacturing USA Today Digital Manufacturin g & Design Chicago, IL Sustainable Manufacturing Rochester, NY Integrated Photonics Albany, NY Regenerative

York, NY Smart Manufacturing Los Angeles, CA Biopharmaceutical Manufacturing Newark, DE Participant members in Manufacturing USA Institutes Lightweight

4 Manufacturing USA Today Digital Manufacturin g & Design Chicago, IL Sustainable Manufacturing Rochester, NY Integrated Photonics Albany, NY Regenerative Manufacturing Manchester, NH Advanced Fibers and Textiles Cambridge MA Flexible Hybrid Electronics San Jose, CA Modular Chemical Process Intensification New York, NY Smart Manufacturing Los Angeles, CA Biopharmaceutical Manufacturing Newark, DE Participant members in Manufacturing USA Institutes Lightweight Metals Detroit, MI Additive Manufacturing Youngstown, OH Advanced Composites Knoxville, TN Advanced Robotics Pittsburgh, PA Wide Bandgap Semiconductor s Raleigh, NC

REMADE Institute Mission By focusing our efforts on addressing knowledge gaps that will eliminate and/or mitigate the

REMADE Institute seeks to motivate the subsequent industry investments that will be required to complete technology

manufacturing eco-system. U.S. Energy Consumption Mfg Energy Consumption by Sector (2012) - 95.

5 REMADE Institute Mission By focusing our efforts on addressing knowledge gaps that will eliminate and/or mitigate the technical and economic barriers that prevent greater material recycling, recovery, remanufacturing, and reuse, the REMADE Institute seeks to motivate the subsequent industry investments that will be required to complete technology development and deploy these technologies across the U.S. manufacturing eco-system. U.S. Energy Consumption Mfg Energy Consumption by Sector (2012) Quads 1 (minus feedstocks) 19.2 Quads Polymers, Metals, Fibers, & e-waste Energy Losses Quads Primary Feedstock Processing (Quads) Raw Mat'l Mining/ Extraction (Quads) GHG Emissions (MMTCO2e)

6 Technical Innovation Today s Paradigm Silos, Low Penetration, Slow Progress Parts manufacurer Product manufacturer Service provider Energy recovery Landfill Collection Mining/materials manufacturing Maintenance Leakage to be minimised Reuse/redistribute Recycle Refurbish/ remanufacture } Systems Analysis } No comprehensive lifecycle U.S. data sets for polymers and fibers } Recycling } Typical recycling rate < 28%, challenges with separation and recovery } Remanufacturing } Domestic remanufacturing penetration rate is ~ 2% } Design } Current design tools do not address reuse/remanufacturing considerations } Manufacturing } Manufacturing scrap treated as waste, often downcycled. Ellen MacArthur Foundation

Typical material reuse efficiency >50% Recovers embodied energy of conversion Provides economic

7 Remanufacturing Remanufacturing: Manufacturing process that restores used or EOL products to like new condition. Typical material reuse efficiency >50% Recovers embodied energy of conversion Provides economic motivation for recovery 2012 Study by US Intern. Trade Commission - $43B US Market, $12B in exports - 2% intensity in primary sectors - Employment: 180,000 - SME roughly 25% of total revenues

8 Reman Industry Sectors Aerospace IT Equipment Automotive Consumer Products Electrical Apparatus Locomotive Systems Machinery Furniture Medical Equipment Heavy Duty/ Construction Equipment Restaurant Equipment Imaging Products & Consumables Tires

Asset Health Monitoring Technologies GPS PS 11/12 Output Harmonic 1 Output Harmonic 2 Output Harmonic 6 Zero 33.3 Low 33.3 High 33.3 Battery Voltage 12 Low 33.3 Nominal 33.3 High 33.3 Battery Voltage 24 Low 33.

3 Normal 33.3 High 33.3 Voltage Differential 12 Normal 50.0 High 50.0 Alt AC Tap Freq Zero 33.3 Low 33.3 Normal 33.3 DC Alternator Current 24 High 25.0 Normal 25.0 Low 25.0 Zero 25.

80 Failed 0.20 Sense Wiring 12 Good 99.0 Failed 1.0 Pow er Generator Good 99.0 Degraded 0.80 Failed 0.20 Belt Good 100 Failed 0 Regulator 24 Good 98.0 Degraded 1.80 Failed 0.20 Sense Wiring 24 Good 99.

0 Failed Hull Assembly Suspension/Steering Engine System Hierarchy LAV-25 Transmission Cooling System Drive Train Fuel System NBC System Hydraulic System Fire Suppression System Transfer Case

Design Signature Analysis Anomaly Detection Condition Assessment LCDN 13/9V SHN A alternator current LCDN 12/12.5 AA tilt sensor A ambient air temp. A main air pres. D parking brake sw D 4/8 dr.

A starter vib. A Engine oil pres A Engine cool temp. A Engine oil level A Hydraulic pump vib. A Hyd. Pump pres. LCDN D fuel cutoff A Engine vib. A trans vib. LCDN 5/9V 6/12.

Steering pres. D oil pres warning high/low sw LCDN 2/12.5 LCDN 8/9V LCDN A coolant ut temp. 1/12V D coolant level A air comp. Temp. Res Brake pressure D Brake failure A hyd. fluid level A hyd.

5 Predicted Temperature Memberships 1 0 60 80 100 120 T [ C] T(t) Target = T(t) NOTE: in a regular LAV the CAN bus could run down along the fuel filler pipe from the ceiling to get under the seat

9 Asset Health Monitoring Technologies GPS PS 11/12 Output Harmonic 1 Output Harmonic 2 Output Harmonic 6 Zero 33.3 Low 33.3 High 33.3 Battery Voltage 12 Low 33.3 Nominal 33.3 High 33.3 Battery Voltage 24 Low 33.3 Nominal 33.3 High 33.3 Zero 33.3 Low 33.3 High 33.3 Zero 33.3 Low 33.3 High 33.3 DC Alternator Current 12 High 25.0 Normal 25.0 Low 25.0 Zero 25.0 Alternator Current 12 Duty Cycle Low 33.3 Normal 33.3 High 33.3 Voltage Differential 12 Normal 50.0 High 50.0 Alt AC Tap Freq Zero 33.3 Low 33.3 Normal 33.3 DC Alternator Current 24 High 25.0 Normal 25.0 Low 25.0 Zero 25.0 AC Alternator Current 24 High 33.3 Normal 33.3 Low 33.3 Voltage Differential 24 Normal 50.0 High 50.0 Rectifier Good 98.0 diode1failure 1.0 diodes2failure 1.0 Regulator 12 Good 99.0 Degraded 0.80 Failed 0.20 Sense Wiring 12 Good 99.0 Failed 1.0 Pow er Generator Good 99.0 Degraded 0.80 Failed 0.20 Belt Good 100 Failed 0 Regulator 24 Good 98.0 Degraded 1.80 Failed 0.20 Sense Wiring 24 Good 99.0 Failed 1.0 Alternator Failure Good 25.0 Degraded 25.0 verydegraded System Failure Good 25.0 Degraded 25.0 verydegraded 25.0 Failed 25.0 Failed Hull Assembly Suspension/Steering Engine System Hierarchy LAV-25 Transmission Cooling System Drive Train Fuel System NBC System Hydraulic System Fire Suppression System Transfer Case Differentials Wheel Dr Hub Assy Marine Drive System Service Brake System Bilge System Compressed Air System Hull Electrical System Turret Assembly Systems Analysis FMEA/RCM Sensor Application and Design Signature Analysis Anomaly Detection Condition Assessment LCDN 13/9V SHN A alternator current LCDN 12/12.5 AA tilt sensor A ambient air temp. A main air pres. D parking brake sw D 4/8 dr. sw. A cold start sw. A ignition sw. A start sw D low brake air D marine dr. sw. LCDN AAA hull vibration 10/12.5 LCDN 15/9V A Engine oil quality 9V D Fire warning D oil filter pres. sw. STE-ICE A - speedometer A Transfer case temp. A starter vib. A Engine oil pres A Engine cool temp. A Engine oil level A Hydraulic pump vib. A Hyd. Pump pres. LCDN D fuel cutoff A Engine vib. A trans vib. LCDN 5/9V 6/12.5 7/12 4/12 LCDN LCDN LCDN A trans oil temp LCDN 3/12.5 A- A trans oil qual.9v TP A - tachometer D Fuel filter delta pres A-Parking brake temp. A Pwr. steering pump temp. A Engine oil temp A Pwr. Steering pres. D oil pres warning high/low sw LCDN 2/12.5 LCDN 8/9V LCDN A coolant ut temp. 1/12V D coolant level A air comp. Temp. Res Brake pressure D Brake failure A hyd. fluid level A hyd. fluid temp. A A A A A hyd. fluid qual 9V. Raw Temperature Memberships T [ C] 0.5 Predicted Temperature Memberships T [ C] T(t) Target = T(t) NOTE: in a regular LAV the CAN bus could run down along the fuel filler pipe from the ceiling to get under the seat back to the fuel level and fuel pumps Diff 1 temp A Diff 2 temp A Diff 3 temp. A Diff 4 temp. LCDN 9/12 LCDN 14/12 A fuel pump 1 current A fuel pump 2 current A fuel level D T(t-1) D T(t-2) D T(t-3) S(t-3) D S(t-2) D S e(t) Adjust Weights Decision Support Application & Integration S(t-1) D S(t) Prognostics Diagnostics

10 Reman Process Development

Development of Widespread Technologies 5 217 18 43 339 R 339 520 F

29 45 226 79 Min 32 W 45 0 20 99 CN 2010 (Gg/a Ni) 7 Yale

Design Tools for Reman, Rcycling, Disassembly, Rapid Sorting of

innovations that will Removal of Trace Contaminants Reprocessing

to manufacture key materials, and } Improve overall manufacturing

11 Development of Widespread Technologies R F Mfg S 6 Scrap U 442 STOCK Min 32 W CN 2010 (Gg/a Ni) 7 Yale University 2016 Information Collection & Standardization Tools 1 8 Design Tools for Reman, Rcycling, Disassembly, Rapid Sorting of Material Streams Separation of mixed materials Directed towards innovations that will Removal of Trace Contaminants Reprocessing of Recovered Materials } Dramatically reduce the energy required to manufacture key materials, and } Improve overall manufacturing energy efficiency through increased material reuse, recycling and remanufacturing.

Manufacturing Focus Areas 5 TECHNOLOGY FOCUS AREAS 5-YEAR INSTITUTE GOALS DESIGN FOR REUSE & DISASSEMBLY Design tools for material utilization/reutilization, design for reman or disassembly SYSTEM

feedstock without loss of quality REMANUFACTURING /EOL REUSE Efficient and cost effective technologies for cleaning, component restoration, condition assessment, reverse logistics RECYCLE & RECOVERY

12 Manufacturing Focus Areas 5 TECHNOLOGY FOCUS AREAS 5-YEAR INSTITUTE GOALS DESIGN FOR REUSE & DISASSEMBLY Design tools for material utilization/reutilization, design for reman or disassembly SYSTEM ANALYSIS INTERGRATION Data collection, standardization, metrics, and tools for understanding material flow MANUFACTURING PROCESSES Efficient use of materials, near net shaping, and use of secondary feedstock without loss of quality REMANUFACTURING /EOL REUSE Efficient and cost effective technologies for cleaning, component restoration, condition assessment, reverse logistics RECYCLE & RECOVERY Rapid gathering, identification, sorting, separation, contaminant removal reprocessing and disposal Reduce primary feedstock consumption in manufacturing by 30% Achieve 25% reduction in embodied energy of targeted materials Achieve cost parity for secondary materials Improve energy efficiency of secondary material processing by 30% Increase size of remanufacturing industry by 100% 4 MATERIAL CLASSES Metals Polymers E-waste Fibers

13 REMADE Institute Members 26 LEADING UNIVERSITIES 44 INDUSTRYLEADERS & 26 ASSOCIATIONS 7 NATIONAL LABS 2017 Sus ta inable Manufactu ring Innovati on Alliance.

Using Testbeds to Aid Technology Transition 12 geographically distributed testbeds* provide mechanism to scale up early stage applied R&D * Enable

14 Using Testbeds to Aid Technology Transition 12 geographically distributed testbeds* provide mechanism to scale up early stage applied R&D * Enable feasibility and validation in a relevant environment and are applicable to the four material classes and four material lifecycle stages targeted by REMADE.

15 How Institutes Create Value for Members Leveraged R&D A legal framework for multi-party collaboration to solve common problems and challenges Potential for sharing R&D project costs/risk between project partners Access to government funds to pay for company projects consistent with Institute investment plan Project Outcomes Program management to assure timely and efficient execution License to use all Institute-funded IP for business and R&D uses for Tier 1 Members License to project-specific IP and other IP only for internal R&D uses for Tier 2 Members Access to wide range of sources of innovation Broad and diverse membership Members at the forefront of innovation in their industries Broad set of academic and national labs expertise New ecosystems to tap for proprietary needs (industry funded)

16 Panelist: Dale Smith, Strategy Manager, Advanced Materials & Fabrication, Product Development for Boeing Commercial Airplanes

17 Panelist: Tim Zemanovic, President of Jet Yard, LLC

18 What are your day-to-day challenges for aircraft recycling and how do they affect the environment and human health?

19 Q & A

Contact AFRA as your resource for information on: Aircraft Dismantling & Recycling Industry Best Management Practices Audit and Accreditation Services

20 Contact AFRA as your resource for information on: Aircraft Dismantling & Recycling Industry Best Management Practices Audit and Accreditation Services Industry Contacts/Networking Aircraft Fleet Recycling Association (AFRA)

Advanced Manufacturing R&D for Clean Energy at the U.S. Department of Energy Government University Industry Research Roundtable Washington, DC

Advanced Manufacturing R&D for Clean Energy at the U.S. Department of Energy Government University Industry Research Roundtable Washington, DC Rob Ivester, Ph.D. Deputy Director Advanced Manufacturing