YOUNGSTOWN, OH — America Makes and the National Center for Defense Manufacturing and Machining (NCDMM) are proud to announce the winners of a $6.6M project call funded by the Office of the Secretary of Defense Manufacturing Technology Program (OSD ManTech). The project call, Improvements in Manufacturing Productivity via Additive Capabilities and Techno-Economic Analysis 2.0 (IMPACT 2.0), consisted of two areas of focus and aims to demonstrate lead time, productivity, and yield improvements for casting and forging manufacturing operations using additive manufacturing (AM) technologies.
AM is of significant interest to the U.S. manufacturing base, particularly within the aerospace and defense sectors since the technology enables shorter lead times and reduces part weight—providing benefits to both new acquisitions and legacy systems. As this sector matures, it is imperative to establish data-based qualifications and performance standards for widespread use in these extreme environments. The goal of this project is to further establish data-driven methods for applying the best attributes of novel AM metal materials.
“For nearly two decades, challenges related to capability and capacity have significantly impacted the U.S. casting and forging industry, creating obstacles in sourcing essential components for critical military equipment and support platforms,” said John Martin, Research Director at America Makes.
“Addressing these challenges is crucial for defense and economic stability. While many additive manufacturing technologies can enhance casting operations and have proven effective across other sectors of the supply chain, augmenting and scaling these capabilities while testing them in real-world demand situations is essential. The IMPACT 2.0 project call is designed to pinpoint the strengths and limitations of these integrated manufacturing approaches. This initiative will empower our members and project teams to research, develop, and execute cutting-edge solutions in the casting and forging sector, a strategic move to mitigate supply chain risks that pose a threat to both the nation’s defense and economy,” Martin added.
Below is the list of award winners and related topic areas:
Part A (Topics 1-3)
Topic 1: Mature and Promote Methods to Add Functional Surfaces and Complex Geometric Features to Forgings
- Team Lead: RTX Technology Research Center (RTRC)
- Project Team: Collins Aerospace, University of Pittsburgh, Camarc, LLC
Topic 2: Disseminate Leading Practices and Promote the Adoption of 3D-printed Sand Molds/Cores
- Team Lead: Honeywell Aerospace
- Project Team: Lightspeed Concept, Inc., American Foundry Society
- Team Lead: Youngstown Business Incubator
- Project Team: University of Northern Iowa 4.0 Center, The Ohio State University Center for Design and Manufacturing Excellence, The University of Tennessee Knoxville, The Boeing Company, HA International, LLC, Humtown Additive, Defense & Energy Systems, LLC, M&P Gravity Works, LLC, 3D Systems, Mathews Additive
Topic 3: Techno-Economic Analysis Tool for Selection of Metal Part Manufacturing Processes
- Team Lead: The University of Arizona Investment Casting Institute
- Project Team: PADT, 3Degrees
Part B – Rapid Casting Demonstration Challenge
- Team Lead: Skuld, LLC
- Project Team: University of Tennessee Knoxville, 3Degrees, Foundry Casting Systems, Metallurgical Solutions, Inc., American Testing
- Team Lead: DDM Systems, Inc.
- Project Team: Department of The Air Force Sustainment Center, 76th Commodities Maintenance Group, Oklahoma City Air Logistics Complex, Tinker Air Force Base
- Team Lead: Renaissance Services, Inc.
- Project Team: UNEW, Aspen Technology, LLC, HTC (castings), A-Labs, Product Development & Analysis, LLC, The Ohio State University Center for Design and Manufacturing Excellence, Value Tool & Engineering