AMMO Monthly Meeting

AMMO WG Teleconference Minutes – 4 April 2018

 

On 4 April 2018, the Additive Manufacturing Maintenance Operations (AMMO) working group conducted a teleconference with over 60 participants.  A summary follows:

 

Naval Additive manufacturing 3D Print File Exchange Initiative – NAVFAC: Alex Viana briefed the group on NAVFAC’s current imitative: 3D Print File Exchange. The four baseline focus areas include web interface (broadest end user community access), proven open source IT technologies (maximize flexibility and scalability), repeatable IT architecture (interoperable ecosystem of similar IT nodes construct), and capture and share user knowledge (technical information and lessons learned). The Naval AM Knowledge Delivery System (NAMKDS) is comprised of three levels, four baselines: digital thread, user interface, lifecycle, and web 3D; four components: 3D print files, technical information, shared knowledge, and advanced planning; four users: operator, logistician, maintainer, and depot; and two goals. The end-users are currently the Navy and USMC with the goal of being a DoD-wide product, the 3D printer, and the NATO coalition.

 

In coordination with SECNAV Innovation Staff & OPNAV N4, NAVFAC has been tasked in FY18 to produce a DoN enterprise-extensible, node-based blueprint for:

  • Integrating and accrediting mature open standard IT technologies
  • Accelerated group collaboration, knowledge capture, technical optimization, and sustainable publishing/sharing of 3D AM data
  • Mainstreaming affordable cyber safe enterprise networked 3D print model data repository, and geo-enabled 3D model based visualization capability

 

There are four concepts of the development pathway, with phase one already completed, phase two in progress, and phase three and four in the future spiral.

  • SPIDERS provides 3D model repository and real-time 3D group collaboration on .mil today
  • 3D visualization planning supporting weapon platform systems engineering, and advance maintenance spatial planning visualization capability
  • 3D model based Expeditionary Advance Base Operations Visualization Planning

 

The incremental project approach is divided into seven blocks with the first being the NAMKDS Definition Blueprint that encompasses desired outcomes such as a warfighter-centric, leverage existing DoD infrastructure, strong stakeholder communication, AM roadmap integration, shared best practices, cybersecurity requirements, etc. to be completed by August 2018.

 

The 3D Print file exchange initiative is a collaborative effort with an overarching goal to improve readiness/sustainment and enhance warfighter capabilities.

 

Additive Manufacturing Maintenance Operations (AMMO) Discussion – Workshop for Warriors: Hernon Luis Y Prado briefed the group on the Workshop for Warriors education program founded in 2008 and located in San Diego, CA. The program is open to transitioning service members or veterans at no cost to them, with a 94% placement rate post-graduation. The program has strict requirements with three tardies equals one absence, three absences is an automatic removal from the program. Workshop for Warriors has Title X authority to select active military 180-days prior to retirement. The program is rapidly expanding with 550 veterans or transitioning members on their waiting list. After four months of 40 hours per week of training, they receive a certification for a production line job. Currently, the program has on average 120 graduates per year, with lack of funding to expand their mission.   Their biggest challenge is reliable funding with the average student needing on average $30,000 per semester. Workshop for Warriors is expected to become eligible for federal funding in August 2018. Workshops for Warriors is a Nationally Viable Advanced Manufacturing Training Pipeline that is ready to be scaled and replicated across America. Their expansion plan includes facilities on the east coast, Midwest, southwest, Rocky Mountains, and northwest. For more information, visit their website: www.wfwusa.org.

 

Direct Digital Manufacturing for Helicopter Engines (Army Mantech) – GE Aviation: Mike Peretti briefed the group on how the Sustainment and AM Community can drive AM and digital technology to benefit shaft programs in production or advanced shaft programs. This four-year program is about 3/4 through their end date. TRL 6 demonstration of Direct Digital Manufacturing (DDM) as a functional manufacturing tool. Reduce risk of implementation. Validated method for DD Manufactured component used in aviation gas turbine engine. The benefits include Enhanced component designs for performance and potential weight savings; flexible, reconfigurable factory infrastructure model with reduced logistical requirements and compressed supply chain; and transitions to T700-GE-701D Black Hawk & Apache; Leveraging/Future Transition Opportunities with advanced turboshaft demonstrators; T408 for Navy CH-53K. The program structure is four years to advance DDM production capability for military turbine engines

 

Year 1 Program Activity:

Task 1 – Candidate Part Selection

  • Quality Functional Deployment (QFD) developed and 15 parts were scored
  • Inlet Swirl Frame chosen for DDM program based on ROI and greatest opportunity for manufacturing advancement
  • ~150 parts reduced to ~25
  • 100’s manufacturing steps eliminated

Task 2 – DDM Manufacturing Process Validation

  • 5 initial test part types for parameter development screening completed
  • Process throughput DOE studies started
  • DOE optimization builds completed
  • DOE data analysis review in-process – expect to complete 1QFY17
  • Additive specific design efforts kicked off
  • First pass design changes completed
  • First sector print expected to be completed 4QFY16
  • First full part print expected to be completed 1QFY17

 

Year 2 Program Activity

Task 2 – DDM Manufacturing Process Validation

  • Complete surface finish validation study
  • Complete process throughput DOE study
  • Complete design change protocol
  • Complete first sector print
  • Complete first full part print

Task 3 – Design Engineering Validation

  • Assess Task 2 process validation results
  • Iterate design process as needed

 

Year 3 Program Activity

  • Engineering Validation
  • Manufacturing Plan Development

 

Year 4 Program Activity

  • Manufacturing Plan Development
  • Single-Lot Production
  • Engine Testing and Validation: component test, rig test, and engine test

 

AM Workshop – OSD(MPP)  – Greg Kilchenstein briefed the group on the upcoming 30-31 May 2018 AM Workshop at the Lockheed Martin Global Vision Center in Crystal City, VA. The two-day workshop is expected to be the next step in the AM implementation into the Department.

 

The workshop will have five teams:

  1. Develop an AM Contracting Guide for Navy / DoD

Working Group Lead: CAPT Armen Kurdian

 

  1. Information Assurance on 3D Technical Data Packages and Blockchain

Working Group Lead: COL Howard Marotto (USMC) and Dana Ellis (NCMS)

 

  1. Pathfinder Scenario Study of AM Repair Part

Working Group Lead: Liz McMichael (NAVAIR)

 

  1. 3D Model Exchange

Working Group Lead: Alex Viana (NAVFAC)

 

  1. Intellectual Property Repository / Cadre of IP SMEs Working Group:

Working Group Lead: Tony Delgado (DLA)

 

To find the two-day agenda and to register for the two-day AM Workshop, visit https://ammo.ncms.org/events/additive-manufacturing-business-model-workshops/.

 

Next Meeting: – The next AMMO WG call is scheduled for 10:30-12:00 am (Eastern Time) on Wednesday, 2 May 2018.

 

POC for this action is Ashley Mitchell, LMI, amitchell@lmi.org, (571) 209-2629

 

 

 

 

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Date/Time
Date(s) - 04/04/2018
10:30 AM - 12:00 PM