NCMS is partnering with the Department of Energy to identify and develop critical manufacturing technologies vital to the affordable manufacturing of alternative energy systems.  We are issuing a call for Concept Papers which will be used to select projects to be funded by this program.  

NCMS is interested in Concept Papers in the following areas:

• Advanced composite manufacturing technologies that will enable process automation for wind blade manufacturing including process automation and advanced curing technologies for higher throughput. 
• Advanced joining technologies to reduce the cost of manufacturing and installing wind turbines. 

Collaborations are expected.

Available Funding / Cost Share Requirements

Approximately $220,000 of funding is available for each project, which will require an additional 1:1 cost share.  

Timeline

Two page Concept Papers need to be emailed to Chuck Ryan, chuckr@ncms.org by 5 pm EST, March 31, 2010.  Please follow the attached template.  Selected teams will be asked to develop a larger proposal (12-15 pages) based on the same template. 

NCMS Membership Requirement

NCMS is a non-profit membership organization.  Project Participants must become NCMS members for those collaborative teams who are asked to submit a larger proposal.   Please see our website for details:  www.ncms.org  

Please direct any questions to Chuck Ryan via email.

Chuck Ryan, Ph.D.
Vice President, Technology
chuckr@ncms.org

Concept Proposal Format and Instructions Template.doc (56.50 kb)

NCMS is requesting help in the production of concepts for a new project opportunity related to web based access to high performance computing tools. The optimal scope is to create within a two to four week window, sufficient visual concepts using rapid development simulation processes and tools. The end product should enable visualization of key interactive feature sets prior to the development of any web application code.

NCMS is looking for a partner that can bring forth experienced people, the right technical solution and best overall process to accomplish the goals and objectives of this project.

For more information please contact:

NCMS Executive Director of Design & Engineering Programs Jon Riley, jonr@ncms.org (734) 995-0556

Current DoD Participants: Marine Corps Maintenance Center, Albany; Marine Corps Maintenance Center, Barstow; Army Project Manager, Light Tactical Vehicles; Marine Corps Program Executive Officer, Land Systems

The DoD is facing severe challenges in their tactical ground combat equipment to provide added ballistic protection and survivability to the warfighters, but the added weight increases rollover events, and decreases vehicle performance such as fuel economy, speed, and acceleration.  In addition, vehicle suspension and engine wear are further taxed by the added weight.

This project will work with the PM-Tactical Vehicles to identify weight savings opportunities on the HMMWV applicable to currently fielded vehicles.  The project will:

1. Design an appropriate solution retrofit structure applicable to the deformation resistance welding (DRW) method for the HMMWV.
2. Fabricate the retrofit DRW subcomponent/frame.
3. Mount the subcomponent/frame onto the platform.
4. Validate the performance of the retrofitted platform.
5. Assess the technology as a repair manufacturing method for other systems such as pipe repair on ships.

For more information please contact:  

NCMS Vice President Chuck Ryan, chuckr@ncms.org, (734)995-4905.

The Air Force and NAVAIR are the primary sponsors of the project  and additional project participants are welcome but must bring value to the collaboration.

NCMS Program Manager Bill Chenevert at (734) 995-7989 or billc@ncms.org

Current decontamination methods used by maintenance personnel result in exposure to dangerous chemicals and pose disposal problems.

We propose to develop and prototype a state-of-the-art automated cleaning system for weapons components, with applicability to aviation, transportation and other industry applications.  Using surface chemistry modeling methods and analysis of existing component substrates, and considering specific contaminants of each component, HPC computer modeling will pre-determine the chemical agents required to affect optimum cleaning with minimal waste generation.  The prototype cleaning system will be capable of mixing the precisely determined chemical solutions designed to break down the specific hazardous substances on contaminated, reusable components.  What we call the “C5” Unit (Chemical Composition Cleaner for Contaminated Components) will employ techniques such as high voltage ionization, phased plasma and/or ultrasonic principles, coupled with applicators, attachments, or enclosures designed specific to user needs. 

A prototype portable, on-site hazardous waste treatment system will be developed; utilizing the onboard chemical elements and/or heat, this unit will completely neutralize or effectively reduce known byproducts generated by the cleaning phase.  (The vehicle may vary dependent on specific industry/component requirements). This will further reduce personnel exposure (for example, in the case of torpedo cleaning, by eliminating the requirement for worker-staffed deep sinks and manual hazmat-grit removal) and waste generation. 

We will test the prototype and analyze by-product levels to meet EPA safe levels.

This project currently seeks commercial and Department of Defense participants with an interest in aerospace; heavy equipment/auto repair; military aircraft/ship/mechanized overhaul and weapon turn-around facilities.

For additional information contact:

NCMS Program Manager, Jeff Walker, jeffw@ncms.org (360) 782-1370, or Heidi Hottinger, heidi@ncms.org (360) 782-1370

The safe disposal of retired naval vessels poses a huge environmental challenge.

This project will provide alternative green metal cutting methods for use during vessel disposal to reduce metal fume emissions in full compliance with Washington State and Puget Sound Clean Air Agency opacity requirements, Federal Clean Water Act, and to reduce costs during the cut-up phases of aircraft carrier disposals.

Several technologies will be evaluated as potential replacements for oxy-fuel cutting. Abrasive Water-jet cutting, inert gas, laser, mechanical cutting, and machining are potential replacement methods.  Process improvement methods will also be evaluated in an effort to control emissions from both oxy-fuel and other traditional cutting methods. Each possible replacement or improvement comes with its own unique set of problems and challenges to overcome. These challenges include efficiency, hazardous waste by-products, and other safety and environmental issues.

This project currently seeks commercial and Department of Defense participants with an interest in the disposal of naval vessels.

For additional information contact:

NCMS Program Manager, Dana Ellis, danae@ncms.org (360) 782-1370

Rapid Access to Readiness-essential (RARE) Parts through Rapid Manufacturing & Repair (RM&R) Technologies

Rapid Manufacturing, also known as additive manufacturing (AM), is a transformational manufacturing paradigm expected to supplant traditional machining and tooling processes for the fabrication of select products. This revolutionary technology builds net shape or near net shape parts layer by layer directly from CAD. Additive technologies allow part design freedoms not possible with traditional fabrication methods. Complex-multiple part configurations can be constructed in a single build, thus allowing reduction in the numbers of component parts needing assembly.

The objectives of the CTMA Rapid Manufacturing & Repair RARE parts program are to explore:

• the range and capabilities of additive technologies and the benefits that can be derived,
• AM technologies as timely solutions to RARE part replacement (legacy parts, obsolete parts, parts no longer available due to diminishing manufacturing resources),
• State of the art AM capabilities for insertion into the DoD organic maintenance base and industry.

Additionally, this program interfaces with machinery OEMs, materials and software developers to:

• facilitate the maturation and deployment of AM technologies, which now range from TRL/MRL 8 to 9 depending upon the part to be fabricated, throughout DoD organic maintenance base,
• advocate and instigate AM industry advancements, AM design guidelines, and standards development to mature to TRL/MRL 9 to 10 respectively.

The CTMA-NCMS program offers a unique platform to achieve the necessary collaborations to develop the potential of these technologies for DoD and industrial applications.

For additional information contact: NCMS Program Manager, Connie Philips. conniep@ncms.org, (386)445-2785 or cell phone – (313)618-8760.

Can you calculate the carbon footprint of your operations?  Do you know how to squeeze out waste using lean principles?  NCMS is making its training programs in sustainability and lean product design available to members and defense facilities.  

The objective of this CTMA effort is to provide the Army with automated test equipment which has the ability to replace the outdated manual test equipment presently used by government and industry. This capability will reduce cycle time for returned night vision devices and significantly reduce costs to the Department of Defense by decreasing destruction of good image intensifier tubes.

Some 10,000 tubes are returned annually from the field and are demilitarized (destroyed) due to a lack of retest verification. However, image intensifier tubes “classified for demil” in the field have subsequently successfully passed MIL-specs during reevaluations.
This automated equipment will be capable of rapidly performing all optical A-tests as required by government and industry for image intensifier tubes.

Implementation of an automated test capability will provide better test repeatability, reproducibility, and improve cycle time versus the present manual test equipment.
Potential customers and/or end users will be U.S. Army, Navy, Air Force, and Marine Corps depots, as well as image intensifier tube manufacturers.

For additional information contact-

NCMS Program Manager, Lee Patch, leep@ncms.org, 734-995-4972.