Since 2012, America Makes has led a consortium of government, educational institutions, and small, medium, and large businesses, all of whom have a stake in the advancement of AM. Each serves as a critical access point for the organization to understand the needs and priorities of the sector, informing its strategy and coordinating action. At present, there are over 80 active America Makes programs, adding to a list of more than 300 programs that have been supported throughout the organization’s history, all of which are directed toward advancing additive manufacturing and communicating its many advantages.

“It’s about moving further and further out from this center of knowledge that we have today, increasing awareness and providing education in the form of ‘What is this technology, how do I use it, where does it fit into my business case and what are the techno-economics of it?’” says Executive Director John Wilczynski of his mission and strategy at America Makes.

The strategy
First established as the National Additive Manufacturing Innovation Institute, the overarching goal of America Makes is to accelerate the adoption of AM in the interest of greater economic competitiveness and security in the United States.

The success of America Makes laid the foundation, in a program called Manufacturing USA, for the establishment of 17 manufacturing innovation institutes in the U.S. which are overseen by various government departments including the Departments of Defense, Energy, and Commerce. According to Wilczynski, “This initiative was necessary in the U.S. to address some existing market failures and shortcomings, so, generally speaking, trying to address global competitiveness and where the U.S. stood with regard to advanced manufacturing.”

AM, also commonly referred to as three-dimensional (3D) printing, is a series of technologies that create 3D objects one layer at a time using digital designs that have been sliced into layers to be replicated by the printing process, depositing and solidifying material, layer by layer, to the desired shape—hence “additive” manufacturing. The process creates complex geometries more efficiently and effectively than traditional manufacturing processes, with the capacity to reduce component weight while offering greater flexibility and speed, competitive advantages that cannot be ignored, particularly for industries like manufacturing, aerospace, automotive, and healthcare.

Given the scope and reach of AM and that this represents only a fraction of its capabilities as a technology still under development, America Makes has the enormous task of sharing these ever-evolving technologies with the AM ecosystem and the world, while the body of knowledge and the various applications continue to grow.

“We need to let that knowledge proliferate into the ecosystem somehow while we’re moving onto the harder things that nobody has solved yet, and so being at different stages of adoption is a huge challenge,” says Wilczynski. He also acknowledges that while the technology is capable, it can’t do everything, nor is that anyone’s intent.

“This is about making sure that the ‘additive’ body of knowledge across technology, and the business case and everything that goes into the end value chain, is accessible and attainable for more and more people,” Wilczynski says.

A resilient ecosystem
Manufacturing is a localized process that has regional and national implications, just as the conditions of the region and country will have an impact on manufacturing operations at the local level. This ecosystem is one that America Makes seeks to strengthen and grow.

“Of course, we have amazing manufacturing regions in our country, and you can’t just run an ecosystem of one particular region; you need to embed your concepts, frameworks, roadmaps, and all your tools in those regions where they’ll be used,” says Ecosystems Director Kimberly Gibson.

With any manufacturing ecosystem, some challenges must be overcome to grow the sector and its economic impact—chiefly the question of human resources and ensuring that adequate numbers of skilled workers are available to sustain the growth that’s being targeted. According to the U.S. Chamber of Commerce, manufacturing represents 45 percent of all unfilled job openings in the country, a total of more than 615,000 job opportunities. What’s more, research by Deloitte found that one third of manufacturing employees are more than 55 years old, which means the dearth of workers is likely to worsen through attrition.

This is a major concern for all manufacturers. The AM industry is short of some 50,000 workers in the U.S., which means that workforce development and education have to be a major component of America Makes’ strategy.

“There are people who need training at various levels, so we do a lot to work on different pathways for learning and making those entry points as accessible as possible. We use the expression ‘From K to gray,’ so our approach is broad,” says Wilczynski.

America Makes is also interested in establishing industry-recognized credentials to ensure that skills and competencies are transferrable and accepted across applications, as there are many. This is where collaboration with the education system will be vital to success, now and in the future, to ensure that those talent pipelines stay flowing and relevant.

“The topic of ecosystem expansion is going to be critical for this to work and it’s really important that we’re building national programs, but it’s also very important that we’re working boots on the ground within regions to do this,” Wilczynski says of efforts to expand the reach and adoption of AM.

Industrializing the technology
A key part of ecosystem development and expansion is the dissemination of information including the transfer of knowledge and technology across the nation, but that’s not without its challenges. The rate of technological development in the AM space is rapid, despite the fairly long lead time for research and development, which means there is a need for patient capital and the ability to quickly and comprehensively communicate the advantages of the constantly advancing technology.

“You want to pull this new technology into different platforms, but you have to make sure the companies that develop the equipment and materials are still in existence by the time the world adopts it, because it’s very hard to be on the bleeding edge of something and stay alive—doing that thing that nobody wants to buy yet or don’t know they need yet or don’t yet crave,” explains Gibson.

Additionally, the work of America Makes has a lot to do with sharing what has been proven, supporting what is still to come, and communicating that message clearly to its members and the various sectors that will benefit.

Acknowledging that there are major advances in the size, speed, stability, and even cost of available systems, Gibson says, “We believe that ‘additive’ is key to manufacturing freedom and the ability to distribute that across the globe in various ways. We don’t believe additive will be used for everything; it just augments existing manufacturing.”

“We’re far beyond the thought that additive is for prototyping,” Wilczynski adds. “It is absolutely for that, but it’s for many more things. It’s widely used for tooling and things like that that support other manufacturing processes, and for direct part manufacturing. There are good use cases across that spectrum where, depending on who you are or what you do, you could apply the various toolsets of additive manufacturing based on what your needs are.”

The biggest challenge, then, is integration, which will be a big part of the organization’s role in the future as it continues to forge a path forward for the AM ecosystem. “We’re very much about raising the overall capability of the U.S. manufacturing base, and doing that is a bit of a different model, but we’ve been able to show significant impact and we’ve paved the way for a lot of other technologies at the same time,” says Wilczynski.

To be sure, there are exciting times ahead. What Wilczynski says about the goals of the organization speaks volumes about America Makes and the impact it seeks for the transforming—and near-limitless—potential of additive manufacturing in the United States.

The post Additive Manufacturing and America Makes – How They Add up to a Great American Future<p class="company">America Makes</p> appeared first on Manufacturing In Focus.

At its core, AM LLC offers custom manufacturing services that cater to various industries. The company’s capabilities span multiple manufacturing types, focusing primarily on plastic and metal parts. Whether it’s through 3D printing, traditional machining, injection molding, laser cutting, or forming, AM LLC prides itself in finding a solution for every customer’s needs. If you have a plastic or metal part in mind, chances are this team can make it happen.

The company offers a dozen different manufacturing processes, and its expertise lies in being able to select the most suitable method based on the project’s requirements. One of its standout features is the ability to work on both prototypes and full production quantities. This flexibility allows customers to test their ideas on a smaller scale before scaling up to mass production, ensuring that their products are optimized before entering the market.

Moreover, AM LLC’s range of services is designed to cater to diverse industries, from aerospace and defense to commercial, medical, and industrial sectors. Whether it’s a military-grade component or a complex commercial product, the team has the experience and knowledge to handle even the most intricate projects. The ability to offer various production techniques gives customers more options, and this versatility makes AM LLC a valuable partner in the manufacturing process.

Behind every successful manufacturing company is a dedicated team of individuals, and AM LLC is no exception. Its team of 31 employees is a close-knit group of experienced professionals, each contributing to the company’s success in different ways. From sales to project management, manufacturing, inspection, and shipping, the team is equipped with the knowledge and expertise to handle even the most complex manufacturing challenges.

One of the company’s greatest strengths is its employees’ collective industry experience. Many members of the team have been in the manufacturing sector for over a decade, while some have been working in the industry for 25 years or more. The company recently hired a quality manager with over 30 years of experience in manufacturing quality, further strengthening its ability to cater to clients’ needs with precision and care.

This extensive experience means that the team can troubleshoot potential problems, streamline processes, and ensure that every step of the manufacturing journey is optimized for success. AM LLC’s focus on hiring skilled and knowledgeable personnel is what allows it to deliver high-quality results consistently. As the manufacturing industry becomes increasingly complex, having a seasoned team provides a competitive edge, enabling the company to provide expert guidance and support to its customers.

When it comes to company culture, the business places a strong emphasis on speed, quality, customer service, and pride in the work. Quality is paramount in the manufacturing industry, and AM LLC takes this aspect seriously. “We have implemented stringent quality control measures to ensure that every part we produce meets the highest standards,” says Gates Frazier, National Sales Manager. This includes thorough inspections and vetting processes overseen by a dedicated quality manager and a detailed inspection team. As a result, customers can trust that the parts they receive will not only meet but exceed their expectations.

Customer service is another key pillar of AM LLC’s success. In an era where automation has taken over many aspects of customer interaction, AM LLC takes pride in offering a more traditional, personalized approach. Unlike some larger companies where customers can face frustrating, automated responses, AM LLC ensures that when customers call, a real person answers the phone. Emails are answered promptly, and the company strives to make every interaction with its customers as smooth and efficient as possible.

This personalized service, combined with a commitment to quality, is what sets AM LLC apart. Its customers not only receive high-quality products but also experience a level of care and attention that is becoming increasingly rare in today’s automated business world. It’s no wonder clients continue to return for more projects, knowing they can trust AM LLC to deliver.

While the company’s main facility is based in Las Vegas, Nevada, its reach extends far beyond U.S. borders. For certain projects, particularly injection molding, AM LLC sources parts from manufacturers in China, a global approach that allows it to offer competitive pricing while maintaining strict control over quality and delivery timelines. Every part, whether produced in-house or sourced abroad, is inspected and vetted at the Las Vegas facility before it reaches the customer.

AM LLC’s customer base is primarily in North America, covering the United States and Canada, and has global sourcing capabilities, allowing the team the flexibility to take on projects anywhere in the world. Alternatively, parts can simply be manufactured in the Las Vegas, Nevada factory. This local and broad reach, combined with a commitment to quality, makes AM LLC a trusted partner for companies that need reliable, high-quality manufacturing solutions across a range of industries.

The business’ growth and success over the years have not gone unnoticed. Since its inception in 2009 and more aggressive expansion starting in 2013, the company has seen consistent year-over-year growth in sales, excepting the challenges posed by the COVID-19 pandemic. A growth increase of 20 percent last year is a testament to its ability to maintain strong relationships with clients and deliver on its promises.

The company has also earned recognition from major industry players. Notably, Northrop Grumman has recognized AM LLC as a pivotal supplier for the F-35 program, one of the most advanced military aircraft in the world. This recognition speaks to the team’s expertise in producing high-precision components for defense and aerospace projects, industries that demand nothing short of perfection.

Additionally, AM LLC has achieved important certifications, including ISO 9001:2015 and ITAR certification. These certifications are critical for working with government contracts and defense-related projects, as they demonstrate the company’s commitment to maintaining the highest standards of quality, security, and compliance. Holding these certifications also opens up opportunities to work with clients who require strict adherence to industry regulations.

Like all companies in the manufacturing sector, AM LLC faces its share of challenges, particularly in finding experienced personnel. The manufacturing industry as a whole has seen a decline in skilled workers, with fewer people entering the trades. This shortage is especially pronounced in cities like Las Vegas, where the pool of experienced manufacturing talent is smaller compared to other regions. However, AM LLC remains optimistic, noting that the influx of people relocating to Las Vegas in recent years has brought more talent to the area.

Another challenge is the rapid advancement of technology in manufacturing, particularly automation and AI. While these technologies have revolutionized certain aspects of production, AM LLC believes that the human element is still essential, especially when it comes to setting up and managing complex manufacturing processes. The expertise and experience of skilled workers remain crucial to ensuring that machines and systems operate efficiently and effectively.

One of the most exciting aspects of working in the manufacturing industry is being part of the development of next-generation products, and at AM LLC, employees get to see the latest advancements in military, space, aerospace, medical devices, robotics, and industrial products. Turning ideas into reality is what drives the team, and they take great pride in knowing that the parts they produce are contributing to the development of groundbreaking technologies.

Indeed, whether producing components for space exploration, advanced robotics, or cutting-edge military equipment, AM LLC is at the forefront of innovation. The ability to work with a wide range of materials and manufacturing processes makes it a versatile partner for companies pushing the boundaries of what’s possible. Its involvement in projects for space exploration in particular is a point of pride for the company. As the space industry continues to grow, the need for reliable, high-quality components is increasing, and AM LLC is well positioned to meet this demand.

“By staying on the cutting edge of technology and constantly improving our processes, we are helping to shape the future of space travel, robotics, and other advanced fields,” explains Tory Sirkin, President of AM LLC.

As the company looks to the future, its focus remains on sustaining its impressive growth, expanding its capabilities, and continuing to provide exceptional service to customers. While there are no immediate plans for geographical expansion, the company recognizes that its current Las Vegas facility may need to grow to accommodate increasing demand.

In addition to expanding its physical footprint, AM LLC plans to continue investing in new technologies and equipment to stay ahead of the curve. As machines become faster, smarter, and more affordable, this team is committed to leveraging these advancements to offer even better service, understanding that staying at the forefront of technology is crucial in the competitive world of manufacturing.

AM LLC’s growth model also includes maintaining strong relationships with customers. Believing that long-term success is built on trust and reliability, by consistently delivering high-quality parts, providing excellent customer service, and building lasting relationships with clients, the company ensures that its growth will continue well into the future.

In a world where manufacturing is becoming increasingly automated and impersonal, Additive Manufacturing LLC stands out as a company that combines cutting-edge technology with traditional values. A commitment to quality, customer service, and continuous improvement has earned it the trust of some of the biggest names in the industry, including Lockheed Martin, Northrop Grumman, Abbott, Collins Aerospace, and many others. So whether you need a prototype or a full production run, AM LLC has the expertise and capabilities to turn your ideas into reality. With a global reach, a dedicated team, and a passion for problem-solving, this is the partner you can trust for all your manufacturing.

The post Innovative Manufacturing, Quality, and Commitment<p class="company">Additive Manufacturing LLC</p> appeared first on Manufacturing In Focus.

Researchers there are creating new methods for design optimization, materials development and characterization, process parameter selection, and parts qualification and certification, that have helped to drive the widespread adoption of additive manufacturing (AM) technologies. Their work has helped to mature the technology by enabling faster, more efficient and reliable production of parts that can be lighter in weight, superior in mechanical properties, and more complex in geometry.

Sandra DeVincent Wolf is the Executive Director of both the Next Manufacturing Center and Carnegie Mellon’s Manufacturing Futures Institute, which brings engineers and scientists from across the university together to advance the digital transformation of manufacturing by applying digital technologies such as artificial intelligence; advanced data analytics; augmented, virtual, and mixed reality; and digital twins to a wide range of manufacturing technologies, including robotics, micro and nano manufacturing, biomanufacturing, and additive manufacturing.

Wolf oversees two AM labs—one on the Carnegie Mellon University campus and a second at Mill 19, where both faculty researchers and engineering students conduct additive manufacturing research in a facility that was built on the former site of one of Pittsburgh’s largest steel mills.

The AM equipment in the labs includes aerosol jet printing, binder jetting, bioprinting, directed energy deposition, electron beam melting, laser hotwire, laser powder bed fusion, and wire arc additive manufacturing. The facilities are available for use by both university faculty and students as well as industry partners.

Next Manufacturing’s research employs artificial intelligence and machine learning to advance part design; process development, monitoring, and control; materials development; qualification and certification of parts; and robotics and automation. These advances will significantly increase build rates, reduce costs, improve properties such as fatigue resistance, allow for customization of the entire process, and ultimately enhance the widespread adoption of AM.

“Thanks to our ability to apply the ever-increasing computer power and AI expertise we have at Carnegie Mellon, we can now gather and analyze vast amounts of data to optimize these complex processes,” explains Wolf, who adds, “It’s astonishing how the work in the lab has evolved. We now spend more time setting up cameras and microphones to collect visual and audio data than we do actually running a build. It’s very efficient. It’s phenomenal.”

“I started at CMU in 2015, and my primary responsibility was to introduce outside industry, federal entities, and other organizations to the research and capabilities that we have, and to meet with those organizations to understand their challenges and interests, and then work to bring those together to develop partnerships that would support our research,” says Wolf.

“At that time, the aviation industry was developing an interest in using metal additive manufacturing, leading to increased activity as companies began calling us to inquire about industry developments and whether it would be significant enough for them to consider serving the additive manufacturing industry, in addition to traditional powder metallurgy industries,” she explains.

“Manufacturing organizations were honestly worried that metal 3D printing might replace what they do, and that machining wouldn’t be needed anymore,” says Wolf. “Fortunately, they’re not being replaced at all. They’re needed more than ever, and their skill set is essential to the system, whether it’s making fixtures and jigs or finish-machining parts that are 3D printed.”

Recognizing the growing activity in this area, in 2015, the Dean of the College of Engineering approved mechanical engineering professor Jack Beuth’s request to establish an additive manufacturing center.

“That was all it was at that time—there was no agreement, no plan, no program,” Wolf recalls. “In January 2016, Beuth and materials science and engineering professor, Tony Rollett, and I committed to diving into this. I agreed to serve as the founding Executive Director of the Center, and we just started building and building.”

Wolf collaborated with the legal department and the office of sponsored programs to develop the membership agreement before presenting it to companies eager to learn about additive manufacturing and what Next Manufacturing was doing in the field.

“We launched the consortium in July 2016, marking our very first Next Manufacturing Center Membership Meeting and Research Expo, with attendees from all over coming to meet our faculty and students, interact with others in the industry, learn about our research, and tour our facilities,” says Wolf. “We hosted some elected officials and top representatives from the FAA and the aviation industry, which is where metals additive was really gaining traction. At that time, we had one small metals additive lab with a couple of machines, two faculty members, and four students using it all.”

Since then, the Center has worked tirelessly to promote its capabilities and efforts to support interdisciplinary research, resulting in 35 faculty and 175 students considering themselves affiliated with the Center. There are now two metals additive labs designed and built under Wolf’s leadership.

“I might have 30-some-odd students qualified to use the metals additive lab, which is a process, so that’s an accomplishment,” she notes. “Kudos to those students who have followed all of our training protocols and gotten qualified to work in the labs. That’s something that sets us apart from many universities.”

Metals additive manufacturing can be hazardous, she adds. Handling powders poses significant environmental health and safety risks, including potential inhalation. “It requires extensive infrastructure, and we have managed to operate safely despite these challenges. We also handle reactive powders like aluminum and titanium, which introduces a whole other level of risk since they can be combustible and even explosive.”

The Center’s equipment is available to all its researchers, with external rates for those in the industry who lack such capabilities. Additionally, professional staff are responsible for maintaining the labs’ equipment and ensuring safety.

“We’re very well known for our development of materials, new alloys, and process monitoring and control,” Wolf says. “I would also say we’re leaders in applying AI to additive manufacturing, which has been a primary focus of our research for the last four years. While we continue with process or alloy development, we are utilizing and applying AI as a tool to accelerate our efforts and do it more accurately. As humans, we alone can’t process all the data we can now collect with available computing power.”

In manufacturing—or science in general—when there’s a need for advanced data analytics and the ability to collect vast amounts of rich data, there’s really no other way to achieve this today, Wolf explains, but fortunately, the Center has the computing power to manage it.

“Now that we can monitor all these aspects, it’s astonishing how the work in the lab has evolved. You spend more time setting up the build in order to collect data than actually running a build because of the amount of information you can gather. The experiments are very efficient. It’s phenomenal how much valuable information you can collect in a short amount of time.”

On the funding side, the Center has been fortunate in securing various grants from different branches of the federal government, enabling it to advance vital research. According to Wolf, the Consortium, which was quite large in its earlier years, positioned the Center to win several federal grants including three with the Department of Energy for over two million dollars each for heat exchangers. There’s also been funding from the Office of Naval Research, for a Lockheed Martin-led project that included Center researchers, as well as a NASA University Leadership Initiative program totaling $6 million over three years and a NASA Space Technology Research Institute program funded at $15 million over five years, which has allowed the Center to pursue qualification of additive Laser Powder Bed Fusion (L-PBF), particularly for aviation. The Center is currently wrapping up an AI-enabled AM program funded at $15.7 million over four years supported by the Army Research Laboratory.

One of the Center’s greatest strengths, says Wolf, is that it “includes faculty with deep expertise in important topics like material development, solidification processing, modeling and simulation, design, and advanced data analytics and AI. It allows us to go both deep and broad at the same time to address AM challenges.”

Additionally, the Center’s commitment to fostering an “extremely collaborative environment” has proven invaluable.

“It shouldn’t be a secret sauce; everybody should be collaborating everywhere, and that’s one of the things that’s really special about the Center,” Wolf emphasizes. “My personal mission the entire time I’ve been at CMU is to bring people together, to find the right people, to help others.”

Part of Wolf’s success is her dedication to continuous learning and staying informed. “It’s never too late to learn,” she says, and after extensive experience across various industries, she feels that Carnegie Mellon is the perfect fit. “I’ve finally arrived. I am in a place that I absolutely love, because it’s incredibly exciting. The innovation is outstanding.”

The students are equally impressive, she adds, enthusiastic about being part of the Center. Seminars are highly attended, allowing students to broaden their knowledge beyond their own research.

“We also see students collaborating significantly. They love it; they love being part of this. Some students have even told us that this Center is the reason they chose us over other grad school options while pursuing additive manufacturing.”

The Center is committed to supporting these students, particularly in their research endeavors. “We train them. We want them to be hands-on and capable, which doesn’t happen at every university,” Wolf says. “We also foster a strong collaborative culture of safety in our labs, which is something we are very proud of.”

She is equally proud of the students’ generosity with their time, skills, and knowledge, as well as their willingness to share what they know with others, whether it’s safely training peers or operating various lab machines. “Every one of them is so grateful for their opportunities that they pay it forward or backward. They’re just so generous and gracious.”

Looking ahead, the Next Manufacturing Center aims to continue with automated and data-driven qualification and certification as a pathway to true adoption of additive manufacturing. The goal is also to attract more students and raise awareness of the vast possibilities within the manufacturing field.

“We have the advantage. 3D printing is the best thing that’s happened to metallurgy in years,” Wolf says. “We have an outreach tool, if you will. We have a technique—even if it’s just desktop plastic 3D printing—that’s so visual and so accessible. For $300 to $500, you can have a desktop 3D printer.”

This accessibility means schools, libraries, and community centers are now being introduced to the field, which can only benefit the broader industry.

“Even if you’re a non-technical parent or teacher, you can acquire one, and it’s for girls and boys,” Wolf says. “Additive is on the move now, and that’s incredibly exciting when trying to engage kids in STEM, particularly in additive manufacturing.”

The post Artificial Intelligence and Real Collaboration Drive Additive Manufacturing Research and Development at Carnegie Mellon’s Next Manufacturing Center<p class="company">Carnegie Mellon’s NextManufacturing Center</p> appeared first on Manufacturing In Focus.

Experts in the marketing and distribution of innovative 3D-printed metal alloys, ceramics, and composites including aluminum, copper, nickel, steel, tantalum, tungsten, and invar36, Elementum has enabled the 3D printing of previously unprintable and unique materials, while increasing the characteristics and availability of the most cutting-edge metal-alloy powders and 3D metal powders thanks to its patented Reactive Additive Manufacturing (RAM) technology.

By utilizing this RAM technology, manufacturers can now enhance their existing applications and create entirely new ones that yield performance outcomes and benefits beyond the already astounding advantages of AM technology. RAM creates alloy powders with sub-micron ceramic reinforcements to print high-performance, reproducible parts at a reasonable cost.

Elementum’s metal, ceramic, and composite powders, as well as their variations, increase the qualities of an additively built product, including stability, hardness, durability, low magnetic permeability, strength, conductivity, and ductility. The produced product is perfectly suitable for the harsh conditions and exact tolerances needed in sectors such as aerospace, automotive, energy, defense, healthcare, and tooling.

Some of the metals used by Elementum include six varieties of aluminum additive manufactured powder that offer a wide variety of high-performance properties; copper, which is extremely versatile and used for applications in nearly every type of industry; nickel superalloys that deliver excellent mechanical strength and creep resistance at high temperatures, good surface stability, and corrosion and oxidation resistance; and tantalum, a refractory metal with high ductility, exceptional biocompatibility, a high melting point, and the most corrosion resistance in common use today.

The company is also looking to work with steel alloy-based additive manufacturing powder that offers excellent mechanical strength, higher resistance at high temperatures, and good surface stability; and tungsten, a high-performance additive manufacturing powder that is the hardest pure metal with the highest tensile strength at temperatures above 1650°C.

In addition to providing powders for additive manufacturing in these different metal alloy groups, Elementum can combine other metals upon request from customers.

“I started Elementum 3D a decade ago now in 2014 with the focus of expanding the materials library for additive manufacturing,” says President and Founder, Dr. Jacob Nuechterlein. “At that time, there were approximately eight different metals that were printed commonly, and so our focus was to expand that capability to match what was in other manufacturing spaces. You can go to a machine shop and choose from 60 different aluminum alloys, much less eight metals total. So that was our goal; that was our focus. We’ve printed over 50 different alloys and have released for purchase 12 products in that timeframe.”

While Elementum has numerous excellent products to highlight, Nuechterlein mentions the company’s supply of aerospace-grade aluminums to an aerospace-dominated market in particular. Originally starting with aluminum, the company now also supplies nickel alloys, coppers, and other materials, with its most popular product now being the 6061 RAM2. “In fact, the 6061 RAM2 was the first material to be fully qualified through NASA standards at JPL (Jet Propulsion Laboratory),” he says.

NASA tasked Elementum 3D with collaborating closely with RPM Innovations, Inc. and their RAMFIRE (Reactive Additive Manufacturing for the Fourth Industrial Revolution) project engineers and scientists to design and fabricate a 36”-diameter aluminum aerospike rocket demonstration nozzle using Elementum’s A6061-RAM2 material. The build was carried out by RPM Innovations using their large-format LP-DED method, which combines wire or powder feedstock along with a focused energy source to produce 3D-printed items. Metal fusion and deposition happen at the same time with DED, while a nozzle operates in strictly controlled atmospheric conditions to drop material into the concentrated beam of a high-power laser. As the tool path moves forward, the feedstock melts and deposits.

While the previous method used laser-powder bed fusion (L-PBF) printing to create lightweight, additively made aluminum alloys that could withstand extreme temperature gradients of up to 6000°F in order to enable large-scale production, the aim was to convert rocket engine technology to a laser powder-directed energy deposition (LP-DED) technique. The RAMFIRE project used Elementum 3D’s A6061-RAM2 to print a large-scale LP-DED aerospike demonstration nozzle with integrated channels.

The aerospike’s rocket nozzle plume exits externally through an inside-out design as opposed to the conventional bell-shaped nozzle, with the primary benefit being that atmospheric and airstream pressure maintain the plume at ideal conditions for the rocket’s full trajectory as it climbs. This makes it possible for engines to operate with extreme efficiency, performing better across a range of pressures and altitudes and carrying larger payloads with a reduction in overall rocket weight.

With its unique RAM technology, Elementum has amassed significant knowledge and experience since 2014, when it began producing high-strength powdered aluminum feedstock that is “impossible to print.” Standard aluminum alloys are extremely vulnerable to hot ripping, a kind of fracture that occurs when heat and pressure build up quickly during laser welding operations. For this reason, the industry deems common wrought aluminum alloys, such as AA6061, to be non-weldable. The solidification process is regulated by Elementum 3D’s RAM chemistry, which results in printed material with strength comparable to—and sometimes even greater than—wrought aluminum, as well as finely grained, crack-free microstructures.

“So that’s been incredible, even over the last year or year and a half, where we’ve seen a massive uptick in adoption of our products and of new products,” says Nuechterlein. “People have begun to accept that you’re going to have to have unique alloys for additive manufacturing, as opposed to just trying to copy-paste what people have done in forgings and castings. So because that’s coming across, people are now fully developing qualification processes. They’re allowing us to help them and to support them in those efforts to do full qualification programs, either through federally funded projects, through programs like America Makes, or through project-based programs.”

The qualification and the acceptance of new products into the manufacturing world for additive manufacturing has been “pretty staggering” over even the last year to two years, he adds. And while metals—and the mining of them—aren’t always viewed kindly, Elementum has also managed to build environmentalism into its processes.

“For our products in particular, we can start with scrap material, scrap aluminum, because we’re starting with a common alloy,” Nuechterlein says. “We’re starting with standard, common materials like 6061 aluminum, which is the most popular alloy of aluminum we use in manufacturing. We start with that, and then we turn it into a powder form, and then we add our special additives to it to make it printable. It is a unique chemistry for printing, but we can start with scrap from other industries, and we don’t have to use bespoke or unique casting billets to form our products.”

It’s an important aspect of the company’s work, he says, and a “big deal” as it means Elementum can use recycled aluminum as its feedstock to make the metal powder. And it’s also often a priority for the company’s clients.

“We definitely have some customers that consider it important for them that we can start with scrap aluminum, or even their own scrap,” says Nuechterlein. “So they may be machining parts out of 2024 aluminum and they want to print parts out of 2024 aluminum as well. That’s something where we can start with.”

And it’s definitely unique to Elementum in the case of aluminums, he adds. “We’re starting from raw aluminum, as opposed to starting from scratch. So that’s something that is unique to Elementum.”

Also unique to the company is its ongoing commitment to advancements in printed materials technology. “We have new products that are coming out. We’re going to be releasing new high-temperature copper products, and we’re also going to be releasing new very high-temperature aluminum products,” says Nuechterlein. “Those are the two in the near pipeline. We were just actually funded to fully build out our Haynes 230 nickel, and then also we were fully funded by DARPA (the Defense Advanced Research Projects Agency) to complete a development as well. So there are maybe four products coming out in the near future,” he tells us.

Elementum is also transitioning from initial qualification into production projects right now, which is an important transition for the entire industry, he says. “We’re seeing a transition from starting to do qualifying and seeing if we like it; now we’re looking at scale and volumes and production contracts.”

Any challenges, he says, tend to be scale-related with the raw materials business in general tending to perform better at larger scale. “You need more production and larger volumes to really get going, I think. That’s a challenge and an opportunity at the moment… we’re right on the precipice, I would say, for raw material companies really beginning to wildly succeed, because volumes are starting to pick up.”

But as Elementum continues to grow and exceed, generally its most exciting projects and programs are ones the team can’t really talk about, he adds, even though they’re breaking records behind the scenes.

“We’re breaking records for rocket technology and in automotive where we’re doing things that are really, I think, strong and exciting, and we can never talk about them,” says Nuechterlein. “I think everyone in the industry faces that challenge—the things that are most interesting you can’t really scream to the hilltops. But safe to say, the most exciting things will be revealed three years in the future.”

Aside from its impressive achievements in the industry, the company also manages to maintain exceptional attention to customer care. “We help with that business case and qualification step, so we don’t just hand you the material and say good luck,” says Nuechterlein. “We tend to want to be a part of the development of the project, the qualification process.”

Overall, Elementum has found that the programs that work best are when the company is included in the program and helps support that customer all the way through to full production. “Customer service and customer intimacy are the most important pieces of what we do, which is odd for a raw materials or a consumable supplier,” he adds. “We win when they go into big, large production runs. We have to get them into full production for it to be a big win for all of us. That’s our focus: to help them win and figure out ways that we can support each other to give them better chances of success.”

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WSU ranks third among all U.S. universities in aerospace R&D expenditures and first in industry-financed aerospace R&D expenditures. NIAR is supporting these efforts through the provision of the resources, equipment, technology, and expertise necessary to advance aerospace innovation.

Associate Vice President of Strategic Communications and Marketing for WSU Industry and Defense Programs, Tracee Friess, offered some historical context: “In 1985, NIAR was founded to increase research at Wichita State while also serving the aviation industry, which is such a big part of Wichita’s and Kansas’ economy,” a region that is referred to as the Air Capital of the World.

With an annual budget of more than $350 million last year, 1,500 employees, many of whom are student interns and alumni, and two million square feet of state-of-the-art facilities and resources across six facilities in Kansas and more recently Huntsville, Alabama, NIAR seeks to advance R&D, testing, certification, and training activities related to airframe technologies.

“Our laboratories, services, equipment, and capabilities are all based on what our clients in Wichita, in Kansas, throughout the U.S., throughout the globe, need from us,” Friess explains.

NIAR also supports WSU in the achievement of its vision to be one of the nation’s premier urban public research universities, known for providing impactful applied learning experiences and driving prosperity. Each year, NIAR employs more than 500 students, which Chief Engineer for Defense Industrial Base Strategy, Mark Shaw, describes as, “the world’s largest intern program, and because our labor largely comes from students, our cost structure is also very fair.”

Students from interdisciplinary backgrounds and a passion for aviation and aerospace can participate in work related to material qualification, advanced materials and coatings, machining and prototyping, impact testing, and many other areas of specialty.

“We are world-renowned in virtual engineering. We have a crash dynamics test lab. We do hundreds of millions of dollars in sustainment research for the Department of Defense (DOD). We have a ballistics and impact dynamics lab that does bird strike and ballistics testing, environmental testing and electromagnetic effects, virtual reality, and full-scale structural testing of aircraft and components,” explains Friess of the ever-expanding resources and capabilities at NIAR’s disposal.

Integrating new technologies
With the advent of new technologies, materials, and approaches comes new and often better ways of doing things. In response, the scope and focus of the organization expands, as it has with additive manufacturing. Additive manufacturing has enormous potential in the aerospace and defense sectors but needs to be scaled to realize that potential to its fullest, the implications of which are beyond imagination.

According to Shaw, “The thing we’re trying to solve is really creating a strong, largely U.S. industrial base for advanced manufacturing—specifically for me, metal additive manufacturing,” by scaling those technologies and the benefits they bring. “We have all the material data and material specs for casting and forging an old product; we’ve been doing these things since the ’50s and ’60s with little to no change. And now, we’ve introduced a new manufacturing method.”

If the additive manufacturing sector were left to develop in accordance with the natural course of things, it would take until 2050 to meet its potential. Unfortunately, the U.S. doesn’t have that kind of time on its side.

As Shaw explains, much of the work he does draws inspiration from the book Freedom’s Forge, a story of how industry propelled American success through World War II, a feat that was only possible because of the rate at which mass manufacturing was scaled.

“We’re still somewhat nascent; additive is new. There are a few people doing it really well, but not enough,” Shaw notes. “Because of what’s going on with Ukraine, we’ve recognized that we can’t even support spare parts for Ukraine, so if it’s us, we’re in trouble. Our supply chain is not ready.”

For organizations like NIAR that support the DOD, their timeline is under pressure to ensure military readiness in support of future conflicts. “So everything we do, everything I do, all the different pieces, actually fit into one mission. And that mission is to scale the metal additive manufacturing space,” says Shaw.

A matter of qualification
To achieve this feat, the DOD has accelerated its investment to more than $500 million to expedite research and testing programs to amass the data and capacity to reinforce critical domestic supply of parts and components more cost-effectively and efficiently, which begins with qualification.

Qualification is a major component of the work NIAR undertakes, and several efforts are underway to advance the sector in this regard. In fact, as Friess notes, NIAR has spent “30 years working with the FAA in order to create a shared materials database for advanced materials,” and its most recent iterations are taking shape.

A common qualification program called Performance-based Additive Qualification and Consolidated Strategy is an effort to collect the necessary data to create a framework for these activities which will result in a public standard that will provide additive manufacturers with information related to the required specifications, accepted methods, protocols, and materials.

“When a company chooses a material from our shared materials database, they can bypass some of the material testing that you would have to do for a new material; as long as they can prove that they are manufacturing the material to the specifications shared in the database, then they can skip some of those initial testing requirements, which makes it a lot more cost-efficient to use these shared materials,” Friess explains.

DOD has sponsored a materials database at NIAR to enable the joint forces to have access to a single repository for this information as the foundation for the implantation of additive manufacturing technology in the interest of national security. The goal is to identify a method whereby old technical data can be converted into new technical data and one of the ways this is being achieved is through digital twin work which is “a big deal,” at NIAR.

Instead of having to take each individual part and conduct an engineering analysis, stress analysis, vibration analysis, and other material testing—and have these things qualified every time, which is costly from a time and money perspective—the digital twin enables this process to be qualified and scaled on a plane-by-plane basis.

“We’re going to have to identify them, we’re going to have to create additive parts, and we’re going to have to put them on and print them. We have to approve them now hundreds of thousands at a time, so that’s something that we’re very much invested in—moving from our digital twin world to actually creating additive technical data,” explains Shaw, who acknowledges that digital twins are just one building block in the process, particularly where mission-critical components are concerned.

“One of the reasons that the DOD is so interested in digital twin technology is to sustain their fleets and the value of additive manufacturing for them is that when they need a part replaced, it is very difficult for them to find someone who wants to go through the trouble to develop the digital data to create that part and then go to the trouble of manufacturing a one-off part for the military,” he adds.

For instance, one part on a B52 would be too costly to make and it is unlikely that a manufacturer would want to spool up the factory for one part, a process that could be done with additive manufacturing if the materials and processes were qualified.

To date, NIAR has taken aircraft including a B1, F16, Blackhawk helicopter, Apache helicopter, and M113 armored personnel carrier, among others, through a full tear-down where the vehicles were scanned and reverse-engineered to create a digital twin.

Leading the way
As the technology is still in its infancy, the industry is just starting to see leaders emerge. Very few manufacturers have the capacity, scope, or sophistication to manufacture parts and components to the required standards and qualifications, which adds another element of challenge to the equation. NIAR’s Advanced Technologies Lab for Aerospace Systems (ATLAS) is like a maker space for manufacturers to come and test equipment, develop prototypes, and determine best manufacturing practices before embarking on capital investments of their own.

Efforts are also underway from an education and workforce development standpoint to determine who the industry experts are, what standards they need to train to, and what that training will look like to solidify the future trajectory of the sector for the benefit of the economy and national security.

“Our goal is to be an economic driver for the university, for the region, and for the state, doing that by continuing to work with our industry partners and develop the solutions and technologies that are needed by them. That’s our primary method of operation: to solve problems for industry,” says Friess of the work that will help the technology and the sector to take off.

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