News

By Eartha Hopkin, Content Coordinator

YOUNGSTOWN, OH – America Makes, the National Additive Manufacturing Innovation Institute, united industry leaders, academic experts, and government representatives across the additive manufacturing (AM) industry during its Fall Technical Review and Exchange (TRX), held on November 12-14, 2024, in Tucson, AZ.  

The Westin La Paloma Resort & Spa served as the backdrop for the event with its beautiful desert landscapes and mountain views. In partnership with the University of Arizona, the Institute highlighted 33 contracted projects over the three-day event. The final day featured a closed session with those individuals who met the registration certification requirements. As a premier collaborative platform, TRX fosters technological awareness across the manufacturing industrial base to drive the future of AM.  

According to Brandon Ribic, Ph.D., America Makes Technology Director, projects within the portfolio highlight the ongoing challenge researchers face in balancing the investment of effort and resources in developing new materials and technologies with the practical benefits they deliver. Specifically, he addressed trends in the AM industry and demand signals from the Department of Defense (DoD) while commending the Institute and its members for their contributions to advancing AM technology growth both domestically and internationally. 

Project presentations focused on several critical areas such as qualification/certification, polymer and ceramic development, sustainability, and process modeling and monitoring. These themes were echoed by keynote speakers, including University of Arizona professors Sammy Tin, Ph.D., and Krishna Muralidharan, Ph.D.; Matt Thomas, Ph.D. of the U.K.-based Manufacturing Technology Centre; and Jason Mann of the United States Air Force.

Increasing industrially relevant, statistically based data
One key challenge addressed during the event was reliability and consistency in AM. Professor Tin and his team highlighted this issue through their research on AM-specific alloys for commercialization, reinforcing the notion that robust qualification and certification are imperative to advance the industry and ensure dependable outcomes. 

Another highlighted discussion was led by Neville Tay, Research Engineer and Program Manager for the National Institute for Aviation Research (NIAR). Tay presented NIAR’s work on the multi-year Joint Metal Additive Database Definition (JMADD) project, which aims to develop publicly available and statistically validated material allowables for a titanium alloy (Ti-6Al-4V).  

Tay explained that his team’s research demonstrated the mechanical properties of Ti-6Al-4V remained consistent across various suppliers, a critical factor for maintaining quality standards. Additionally, they discovered methods to enhance its robustness by adjusting the metal powder composition. 

Inspired by the JMADD project, John Shingledecker and Alex Bridges of the Electric Power Research Institute (EPRI), presented their team’s work to enhance statistical data for the DS Nickel-based Super Alloy ABD-900AM project. The project focuses on developing materials capable of withstanding high temperatures in gas turbine engines, as the ABD-900AM alloy has shown superior creep performance compared to other nickel superalloys. These efforts highlight the importance of building upon existing data analysis to improve material performance and have received support from Northrop Grumman.  

Exploring AM value across novel product development
Another topic explored during TRX examined the role of AM in novel product development. Zach DiVencenzo, President of JuggerBot 3D, introduced an initiative centered on advanced filament machines that utilize thermally cured thermosets and thermoplastics. By integrating two-part resin systems with pellet-fed extrusion technologies, his team is investigating the possibilities of hybrid components with enhanced strength, flexibility, and thermal resistance suited for diverse industries.  

Ross Brown from Marotta Controls also presented insights from project Additive Manufacturing Phase 4, Application Development and Material Study, which examines how AM can optimize design by reducing weight and customizing the acoustic signature to prevent unwanted resonation in sensitive naval applications.  

Along these same lines, Joseph Beaman and Desiderio Kovar from The University of Texas at Austin shared their research findings on selective laser flash sintering (SLFS), a technique designed to produce complex, multi-layer ceramic parts quickly. Their presentation indicated the potential of AM to hasten product development while minimizing material waste. Recent successes in creating intricate parts demonstrate SLFS’s innovative potential and highlight essential challenges related to scaling and maintaining quality. Solving these issues is crucial for maximizing the benefits of AM in various industries, improving efficiency, and enhancing production. 

Development of AM processes for non-metallic materials
Broadening the scope of AM materials in relation to post-processing was addressed during a presentation by Cantwell G. Carson, Ph.D., of United Protected Technologies. Carson discussed his work on the Advanced Nanocomposite Coatings for Navy Application project, which aims to improve the performance of non-metallic materials beyond traditional cadmium (Zn-Ni) since it is environmentally harmful. 

One of his team’s key findings included the effectiveness of P51M in protecting against cavitation erosion, particularly in critical applications such as marine propeller blades and nozzles. Their research also showed the potential of new substances to enhance performance and extend the lifespan of essential components, ultimately reducing operators’ replacement costs.  

Understanding sustainable AM
America Makes has launched the Environmental Additive Research for Tomorrow’s Habitat (EARTH) Project to explore the role of recycled polyethylene terephthalate (rPET) in enhancing sustainability through AM. Led by IC3D Printers, the initiative aims to tackle waste reduction and lower carbon footprints across industries. The project considers the challenges and opportunities of using rPET to create a sustainable and cost-effective supply chain that aligns with DoD performance standards. 

According to Luke DeBruin, Extrusion Engineer with IC3D, initial filament trials have shown promising results with rPET demonstrating low deformations without additives, making it a potential option for 3D printing applications. Ongoing efforts highlight the significance of sustainable materials like rPET in advancing environmentally friendly practices in AM, paving the way for a future where sustainability and innovation coexist. 

America Makes convenes the voice of industry
From a technical perspective, the Fall TRX showcased AM’s multifaceted evolution, focusing on the significant role of AM in developing innovative products, enhancing relevant industrial statistical data, and improving AM processes for non-metallic materials.  

“We’re trying to get the data either to prescribe how we will conduct manufacturing operations or learn from our actions to change design for the manufacturing processes,” said Ribic.  

This year’s conference also featured a leadership panel co-moderated by Ribic and Ben DiMarco, Technology Transitional Director at America Makes. Panelists included John Wilczynski, Executive Director at America Makes, Adam Hicks, Government Chief Technology Advisor, and Robyn Vialva, Ph.D., Government Program Manager, both from the Air Force Research Laboratory. Together, the panel shared America Makes’ achievements while reinforcing the Institute’s commitment to leadership through strategic long-term planning. They also emphasized the unique benefit of leveraging the diverse expertise within the America Makes membership to tackle complex issues and drive innovation while bridging industry gaps. 

“We’re shifting from a year-to-year approach to pursuing long-term goals that align with key priorities of the Institute as we move forward,” noted Wilczynski. “We are committed to raising the overall capability of the U.S. manufacturing base, and to date, we’ve been able to demonstrate significant impact. As an Institute, we are proud of the work we have accomplished. We know there is still much to do but we are excited about what’s to come.”