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NCMS is forming a new project, IUID Marking for Legacy Parts – Navy Pilot, to automate much of the non-recurring engineering for the sub class of parts that have nameplates. The project concept is to (1) use intelligent optical character recognition (OCR) technology to find nameplates on raster image scanned copies of legacy TDP, capture a snapshot of the drawing in that area, create an AutoCAD drawing of a new nameplate enhanced with an IUID mark, and create an Engineering Change Order documenting necessary TDP changes plus (2) extract relevant information necessary to populate the Navy Interactive Computer-Aided Provisioning System (ICAPS), populating a spreadsheet with the data.

For additional information please contact:

Tony Haynes
Director, Advanced Manufacturing Technology Programs
(734) 995-4930 direct, (734) 730-0759 cell
tonyh@ncms.org

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October 27, 2011
University of Michigan – North Campus Research Complex, Ann Arbor

OVERVIEW

For researchers, chemists, engineers, industry CEOs, students, educators, entrepreneurs, policymakers – anyone interested in advancing innovation for a sustainable future in Michigan – this conference is the opportunity to hear and share ideas on how we can best “green up” Michigan through green chemistry and engineering. Conference attendees will learn how green chemistry and engineering not only protects human health and the environment, but can also help businesses create new markets, reduce costs, and gain a competitive edge.

HIGHLIGHTS

• Welcome by Mary Sue Coleman, President, University of Michigan
• 3rd Annual Michigan Green Chemistry Governor’s Awards Presented by Governor Snyder
• Keynote presentation by Julie Zimmerman, Acting Director for Yale’s Center for Green Chemistry and Green Engineering
• Over 20 breakout session speakers
• Poster session and student poster contest

Registration fee is $100.

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The public and private sectors will partner to lead the resurgence of American manufacturing, creating new technologies and most importantly, jobs.

NCMS will work continue to work with other national organizations, the White House, and our consortium members to realize these goals.

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Automotive manufacturers and their suppliers are pressing to innovate in order to increase vehicle fuel efficiency to meet federal CAFÉ guidelines by integrating lightweight materials into new vehicle designs. These lightweight materials pose unique challenges and opportunities that must be addressed. The solutions for some of these challenges may be found in other industries such as aerospace and defense or in new tools and processes.

The National Center for Manufacturing Sciences (NCMS) has assembled an innovative suite of software tool providers and cross industry innovators to help manufacturers of all sizes to realize the benefits of lightweight materials while lowering costs, minimizing risk, and speeding commercialization. For the past two years NCMS has been managing the Light Weight Automotive Program (LAMP) awarded by the Department of Energy (DOE), Office of Energy Efficiency and Renewable Energy (EERE), and is administered by the National Energy Technology Laboratory (NETL).  There are currently seven projects operating under this program.  Each of these projects is leveraging the use of High Performance Computing (HPC) modeling and simulation (M&S), to support the selection and optimization of lightweight materials for their products during the product design phase. The tools developed in this NCMS program will allow companies of all sizes to use this cutting edge capability which in the past was cost prohibitive and generally not available.

For the next phase of this program, NCMS is working in partnership with the DOE to bring together 2-3 additional R&D collaborative projects to continue to accelerate development of the knowledgebase and infrastructure for lightweight materials and manufacturing processes for use in automotive applications.  The objective for each project must be to develop and validate remotely accessed virtual technologies (termed Apps or Sims) leveraging existing M&S capabilities that can significantly reduce the design, development and / or manufacture of lightweight components without compromising cost, performance, safety, or recyclability.  The target is to create the means for numerous small and medium sized manufactures to be able to remotely access these tools.

The goal at NCMS is to assemble cross-industry collaborative teams for each project.   While some participants are not specific to automotive and others are not in automotive at all, every successful project team benefits from a broad set of eyes.  Many of these challenges / benefits addressed within NCMS projects have broad applicability.

MODELING & SIMULATION ENABLEMENT REQUIREMENT

The use of M&S will be a component of each project to develop and demonstrate how these tools can reduce product design time, optimize the material and manufacturing process, reduce cost, and improve environmental sustainability.  Incorporating at least one enabling mechanism granting affordable access to the supplier level will either be an explicit part of each project, or an underlying task will develop and demonstrate these tools across a selection of the projects. Once advanced M&S tools are developed, they need to be validated to assure the tools are accurate and reflect performance.  Each of the projects will require validation of these tools.  Finally, each project shall provide the required electronic, virtual web-based training for automotive suppliers to understand and leverage the developed tools.  In parallel with NCMS’ ongoing partnership with DoE are our efforts to bring modeling and simulation capabilities to the nearly 300,000 small and medium sized manufacturers in the U.S.). 

DEADLINE

The deadline for submission of project ideas is Friday, December 17, 2010 at 5 PM EST.   All submissions should be sent electronically to:  Jon Riley, Executive Director, Design & Engineering Programs Jon Riley, jonr@ncms.org.   For more information about the required content, process, timetable or other questions please contact Jon Riley via email (above) or at 734-995-0556.

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NCMS Creates National Network to Promote Advanced Digital Manufacturing
Published October 19, 2010

The National Center for Manufacturing Sciences is stepping up to the plate to help revitalize America’s manufacturing sector. The 24-year-old organization has created a program aimed at putting high-performance digital computing capability into thousands of lower tier manufacturing companies. Currently, only about one-third of the nation’s 300,000 small- and medium-sized manufacturers utilize high-performance computing tools such as product modeling and simulation.Without such capability they are losing to foreign competitors that are using technologyto place themselves into the international supply chains of the major OEMs.

“We have a window of time to revitalize our competitiveness,” says NCMS President and CEO Rick Jarman. “I don’t know how long this window is going to last, but I’m determined from an NCMS standpoint to do everything I can to make the nation competitive. I’m determined to try to fix the problem.”

NCMS, which was created by an executive order signed by President Ronald Reagan in 1986, is building a nationwide network of “Predictive Innovation Centers” (PICs). These public-private collaborations will provide U.S. manufacturers with high-performance computing tools aimed at increasing product design cycles, improving manufacturing processes and reducing the need and costs of laboratory testing of new products. Large companies are using these tools, but not many small manufacturers that provide them with materials, parts and components.

NCMS will establish 10 to 12 PICs in the country over the next three years. It is in the process of raising $12 million a year for three years to launch the centers and
make them self sufficient.

“It’s a pretty inexpensive way to get our companies competitive again,” says Jarman.

NCMS is working in partnership with large OEMs such as General Electric, Caterpillar, Proctor and Gamble and Lockheed Martin; and hardware and software vendors such as Intel, Microsoft, Cray, SGI and Altair. It is also seeking financing from state and federal government agencies.

“We have identified the need and garnered the support to bring advanced computing power to the supply chain,” says Jarman. “It will change everything. The potential is huge. This is amounting to the kind of transformation not seen since the assembly line.”

Each of the centers will have a different focus depending on the industrial cluster in the region. Some will work on developing the capability of large OEM supply chains, and others on applications associated with energy, materials and automotive. NCMS will be the “hub” that collects lessons learned, “which will help us generate the education and the value of buying products in bulk for the usage of the many,” says Jarman. “It builds upon NCMS’s collaboration model that has put technology users, developers and providers on the same project,” he explains. “That is why our projects have been so successful. That is why you never hear from NCMS that we have a technology transfer or technology adoption problem because we design our collaborations for the fact that something is going to become commercialized or be put into a product or process. We’re taking a page out of the same book when it comes to this.”

Jarman says NCMS has had a “full-fledged pickup” from interested parties. The NCMS-created Alliance for High-Performance Digital Manufacturing has grown to 30 companies and interest is being expressed from government agencies and organizations like the Ohio Supercomputer Center. “We have parts of the PICs up and running and we’re making the business case, but the response has been very good from the OEMs who are willing to do this and are willing to help because they need a more competitive supply chain,” says Jarman.

NCMS has found that the commercial market for high-performance computing tools accounts for only 3 percent of the total computer market. Most of the users are large manufacturers. Those using high-performance computing tools have improved product cycle times by 66 percent, and reduced the cost for lab testing of new products by 98 percent.

As the large OEMs continue to push innovation into their supply chains, it is more important for the small companies to adopt these tools. Foreign countries have aggressive programs aimed at deploying digital computing tools deep into their manufacturing sectors. The U.S. has no such program.

“U.S. manufacturers specifically want this from an organization like NCMS rather than an academic institution or government agency,” according to a survey of 300 manufacturing companies conducted for NCMS by Intersect360 Research. “There is a sense of trust associated with a nonprofit whose stated mission is the enhancement of manufacturing in the United States.”

Revitalizing Manufacturing Podcast

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NCMS seeks assistance for ongoing project related to web-based access to high performance computing tools. The optimal scope requires part time support (1-2 days / month) to review and document the generic steps followed to validate a computer model.  These generic steps must then be embodied in an “application” that can be broadly used to validate computer models in simulations such that the information generated can confidently leveraged.  The respondent should have a strong understanding of computer modeling, simulation and engineering, design space exploration methods, and particular knowledge of the use of complexity as a design metric.  Understanding the complexity-based methods used by the Ontospace software tools as supplied by Ontonix LLC is required.

NCMS is looking for a partner that has the right technical capabilities, can work with experienced people in this field, and offer best overall process to accomplish the goals and objectives of this project.  All interested parties must reply by July 24^th.

For more information please contact:

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

The post Tech Transfer Project Opportunity appeared first on National Center for Manufacturing Sciences.

NCMS is seeking participants for a new forming NMRPP project, Catapult Alignment Position Measurement Automation.

The current aircraft carrier catapult alignment method is marginally reliable due to multiple degrees of error and limited data.  Over the 100 meter length of the catapult trough, mechanics repeatedly align a fixture to reference lasers and manually conduct gap and alignment measurements of catapult trough components at fixed points.  Trough components, as well as reference points, significantly shift over the data collection period as a result of thermal effects. Accuracy also suffers from laser instability, difficult fixture centering, mechanical measurement error and recording errors.  A more comprehensive, accurate and reliable representation of component position is needed to determine position corrections in a shorter time.  More accurate data and increased data points would result in better alignment, fewer position correction iterations, fewer alignment checks, and less overhaul schedule risk. 

This project anticipates development of an automated measurement system to increase the speed, accuracy and quantity of component position measurements.  Possibilities would include:

• Automated distance measuring and data acquisition devices, providing increased accuracy over cross-sectional distance
• Photogrammetry
• Laser alignment technologies
• Various other applicable technologies used in metrology, independent or in conjunction as a suite to acquire data points over 100 meters
• The above real-time data acquisition systems to be transmitted to a portable laptop or storage device.

The objectives of the NMRPP Catapult Alignment Position Measurement Automation project are:

• perform detailed requirements analysis and validation of current catapult alignment procedures
• identify cost effective automated metrology technologies
• define the tools, standards and processes to support proper alignment of catapult components.

Additionally, this project seeks to enagage metrology experts, laser and optics technologies, and software developers to achieve the necessary collaborations to develop the optimum technology solution to achieve improved catapult alignment position measurement. This project currently seeks commercial and Department of Defense participants with an interest in metrology, laser alignment, or other technologies related to an extended-length measurement process.  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.

Heidi Hottinger heidih@ncms.org (360) 782-1370.

Photo credit U.S. Navy.

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NCMS is seeking participants for a new forming NMRPP project, New Technology Metal Deposition Repair for Navy Ship/Submarine Components.

Current methods of Metal Deposition Repair (MDR) for worn and corroded components are primarily limited to electroplating/conventional welding processes, which have significant limitations for component repair.  New MDRs are needed for valve bodies, valve balls, pump housings, compressors, impellers, shaft components/seals, and many other general wear and sealing areas on ships and submarines.

A number of existing metal deposition capabilities are available which could be applied to Navy component repair, building on existing, proven capabilities.
This project anticipates development of a wider range of repair options for problematic applications.  Significant ROI potential is possible by salvaging components previously scrapped, increased repair longevity, increasing operational availabilities and reducing repair costs of current repair processes (a previous aluminum laser deposition resulted in a cost savings of $35K per torpedo/target shell).  The objectives of the NMRPP New Technology MDR project are:

• perform component selection/ROI analysis
• develop repair process applicable to selected components, including performing metallurgical analyses
• obtain NAVSEA certification for up to three Fleet components.

Additionally, this project seeks to engage machinery OEMs, materials and software developers to achieve the necessary collaborations to develop the potential of these technologies for DoD and industrial applications.  This project currently seeks commercial and Department of Defense participants with an interest in electron beam deposition-welding, direct metal deposition, friction stir processing, metallurgical analysis, laser deposition, kinetic-spray, high velocity oxygenated fuel, and similar technologies related to component repair processes.  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. 

For more information please contact:

Heidi Hottinger heidih@ncms.org (360) 782-1370.

Photo credit U.S. Navy.

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NCMS is seeking participants for a new forming NMRPP project, Environmentally Friendly Cutting Solutions.

The current method employed for large-scale cutting and ship disposal (Oxy-Fuel) creates large quantities of visible emissions, metal fumes and debris.  Federal and State Clean Air Acts prohibit visible emissions greater than 20% opacity.  Attempts to control emissions to comply with these requirements have results in increased project costs and longer schedule duration.  This project will:

1. Develop and implement process improvements to control emissions associated with current cutting methods
2. Investigate steel cutting technologies with productivity comparable to standard flame cutting while meeting environmental requirements
3. Demonstrate effectiveness of these technologies on multiple cutting applications, where opacity levels, dry dock discharges and hazard waste reduction levels meet requirements of local, state and federal laws.

This project currently seeks commercial and Department of Defense participants with an interest in diamond rope cutting, plasma-arc welding, waterjet cutting, laser cutting, or other technology related to large equipment cut-up with minimized opacity generation.   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.

For more information please contact:

Heidi Hottinger heidih@ncms.org (360) 782-1370.

Photo credit U.S. Navy.

The post NMRPP Project Opportunity- Environmentally Friendly Cutting Solutions (EFCS) appeared first on National Center for Manufacturing Sciences.

NCMS announces the formation of a new collaboration- Navy Maintenance and Repair Partnership Program (NMRPP).  Launching in the Pacific Northwest, with Project Managers assigned to NCMS West, in Bremerton, WA., NMRPP supports Naval shipyard and other maintenance and repair operations essential to sustain the most critical ships and undersea weapon systems in the Navy and assure maximum availability to warfighters.

NCMS collaborative projects for research, development, evaluation and technology insertion highly leverage combined resources, knowledge and capabilities of participants to yield results and benefits faster and at lower cost than typical individual efforts.  NMRPP has been developed by NCMS to demonstrate, through selected technology deployments involving the Navy Maintenance and Logistics Community, that a wide range of commercial manufacturing technologies and best business practices currently unavailable to the Navy can have a substantial impact upon operating and sustainment costs and the readiness of major weapon systems.

Three projects are forming and are currently seeking potential industry and DoD partners:  Environmentally Friendly Cutting Solutions, New Technology Metal Deposition Repair for Navy Ship/Submarine Components, and Catapult Alignment Position Measurement Automation.

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On 28 – 29 April, FRC East hosted a Technology Showcase sponsored by the National Center for Manufacturing Sciences (NCMS) through its Commercial Technologies for Maintenance Activities program (CTMA).  The showcase brought leading technology companies into FRC East to see first hand the challenges our maintainers face in order to identify innovative commercial solutions.

The Technology Showcase opened with Col. Loch providing an overview of FRC East operations and Mr. Greg Kilchenstein from OSD’s Maintenance Policy and Programs office providing an overview of maintenance technology’s role in DoD’s overarching strategy and he outlined the Commercial Technologies for Maintenance Activities program as proven technology transition venue.  NCMS member companies were given a comprehensive tour of FRC East operations and facilities.  Next on the agenda were table top displays, strategically located throughout the depot to ensure easy access for all base personnel to see the technologies  The table top displays provided industry representatives a unique opportunity to learn about challenges faced directly by the maintainers.  The first day concluded with a networking event at the “The Pitt.”  The second day was dedicated to one-on-one industry presentations with base personnel regarding solutions with immediate potential for deployment at FRC East.

The Technology Showcase was a powerful example of how the CTMA Program fast tracks innovative technical solutions from private industry directly into the hands of DoD personnel to increase systems availability while reducing cost.

NCMS members displaying technology included DIT-MCO International, Aging Aircraft Consulting, LLC, Superior Controls, iMAST/ARL (Penn State), Stratasys, Eclypse International, Adapt Laser Systems, Automated Precision, Inc., Aerowing, Imaginestics, LLC, Spatial Integrated Systems, Inc.,  Spectro Inc., GSA Service Company,  POM Group, REI Systems, Inc., and Pendaran Inc.,

Three CTMA projects have been formed to immediately meet FRC East needs:

• Wiring Shop Modernization – upgrade the capability to build and test wiring harnesses, currently very labor and time intensive.
• Automated Robotic Blade Stripping System (ARBSS) – Provide a reliability upgrade and training.  In addition, assess the challenges for wider deployment of automated paint stripping technology.
• Large Area Inspection of Composite Parts- evaluate and identify improved methods for detecting damage to composite aircraft components.

The Commercial Technologies for Maintenance Activities (CTMA) Program is collaboration between the National Center for Manufacturing Sciences, its member companies, and the Department of Defense (DoD).  Under an historic Cooperative Agreement between NCMS and the OSD Office for Maintenance Policy and Programs,, NCMS and its member companies co-sponsor technology development, deployment and validation with DoD organic maintenance activities.  The current focus is the use of maintenance related technologies to reduce the costs associated with maintenance and rebuild of weapons systems as an element of the overall DoD maintenance strategy.

By partnering with NCMS government services members, the organic DoD maintenance activities are able to quickly assess the benefits of new manufacturing technologies in their own facilities, working side-by-side with industry leaders solving manufacturing problems through collaboration.

NCMS is the largest cross-industry collaborative research and development consortium in North America, and is the only consortium in the U.S. devoted exclusively to maintenance technologies, processes and practices. NCMS has nearly 25 years of experience in the formation and management of complex, multi-partner collaborative R&D programs, and is backed by corporate members representing virtually every manufacturing sector.

The next Technology Showcase will be 8 – 9 June at the Marine Corps Logistics Base, Albany Maintenance Center in Albany, Georgia.

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NCMS is partnering with the Department of Energy (DOE) to identify and develop critical manufacturing technologies vital to the affordable manufacturing of alternative energy systems.  The call for Concept Papers 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 the web site for details:  www.ncms.org

Please direct questions to Chuck Ryan via email.

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

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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

The post Emerging Tech Transfer Project Opportunity appeared first on National Center for Manufacturing Sciences.

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.

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NCMS is seeking participants for a new forming project, Trivalent Chrome Phase II. This project will complete the initial work of Phase I, where the team developed a new chrome plating process using a trivalent chrome bath to replace the highly-toxic hexavalent chrome bath. The trivalent chrome process must produce hard chrome components that perform equally or better to the older process while still meeting all military specs. 
 
In Phase II, rigorous testing will be performed of the trivalent process to determine its applicability as a viable replacement for hexavalent chrome plating.

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.

For more information please contact:  

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

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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

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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

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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.

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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.  

For more information, contact Paul Chalmer at NCMS, paulc@ncms.org or (734) 995-4911, or Mike Gnam, mikeg@ncms.org or (734) 995-4971.

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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.

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The National Center for Manufacturing Sciences (NCMS) is currently managing (on behalf of the U.S. Navy) a project designed to convert a legacy, paper-based maintenance manual to an electronic form that is compliant with the S1000D international standard for technical manuals. To better understand the scope and scale of the level of effort, NCMS seeks information on rough order of magnitude cost and an approximate schedule.

Information gathered will be used to structure an eventual award where a contractor will work hand-in-hand with U.S. Navy resources at Keyport Naval Undersea Warfare Center to perform a portion of the conversion and to train Keyport resources in the course of that work Infrastructure for authoring and content management is already in place with Arbortext for authoring and Contenta for content management.

For more Information contact:

Tony Haynes, tonyh@ncms.org (734) 995-4930.

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Automotive manufacturers and their suppliers are pressing to innovate in order to increase vehicle fuel efficiency to meet federal CAFÉ guidelines by integrating lightweight materials into new vehicle designs. These lightweight materials pose unique challenges and opportunities that must be addressed. The solutions for some of these challenges may be found in other industries such as aerospace and defense or in new tools and processes.

The National Center for Manufacturing Sciences (NCMS) has assembled an innovative suite of software tools and cross industry innovators to help automobile OEMs, tier one suppliers, and component manufacturers realize the benefits of lightweight materials while lowering costs, minimizing risk, and speeding commercialization.

Through the use of High Performance Computing Simulation (HPCS) manufacturers will select the best lightweight materials for their products, during the design phase of development. The tools developed in this NCMS project, utilizing HPCS will allow companies of all sizes to use this cutting edge capability which in the past was cost prohibitive and generally not available.

NCMS has immediate project opportunities for companies who want to integrate lightweight materials into their product designs. The US Department of Energy, with the goal of helping the automotive industry to increase fuel efficiency, is sponsoring this groundbreaking program through the NCMS which has more than 20 years of management experience with projects of this magnitude and scope.

For more information please contact:

Senior Program Manager Steve Hale, 734-995-2195, stevenh@ncms.org

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Project Category: Condition and Prognosis Based Maintenance.

Current industry participants are Eclypse International, Boeing, and Aging Aircraft Consultants, Inc.

For more information please contact:

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