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Doyle Maleche, senior engineering program manager from our Bremerton, Washington office is working directly with high school students to share his extensive practical engineering experience to help them to successfully build and operate underwater Remotely Operated Vehicles (ROVs). The chance to create something so challenging is very motivating and educational for the students, and they often come in early to school and stay late to work on their creations. Students not only learn technological skills but also collaborate in teams for practical problem-solving that they could not learn from a book. Often parents and others are drawn into the ROV challenge competitions and as part of the learning process.

Instructors include many current and former Navy personnel, plus employees from Raytheon, Lockheed Martin and others.

The Kitsap County (Washington State) program began in 2006 with a $24,000 grant awarded to the Naval Undersea Warfare Center (NUWC) at Keyport. In 2011, NUWC hired NCMS to implement the program. At the outset supplies were purchased to build ROVs for only two high schools – PVC pipe, washers, Radio Shack motors, toy propellers, 35mm film canisters, wires and tools. Despite the inexpensive materials, the project’s effect on motivating students was so successful that it spread to other middle and high schools in the district. The program has doubled in size every year and by 2012, it will be in 14 elementary, middle, and high schools in Kitsap and Jefferson counties, engaging over 2000 students. The program has sparked interest from the Boy Scouts of America and Navy Sea Cadets, and is expanding to reach students and educators in Alaska, Hawaii, and San Diego.

NCMS’ newest collaboration effort is partnering with Dr. Jodi Carson and Olympic College’s Math, Engineering, and Science Achievement (MESA) program which is also a nationally recognized academic enhancement program. MESA looks beyond traditional student populations to meet future and global workforce demands in the field of science, technology, engineering, and mathematics (STEM).

The group is actively seeking additional sponsorships and donors to allow continued growth of the program. Sponsors will be given recognition as well as knowing they are contributing to the development of skills that are critically needed for the United States to compete in the worlds industry and marketplace.

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As a member company, and a participant in successful NCMS projects, Profile Composites was able to take advantage of the extensive network of NCMS relationships and contacts among government, education and industry, both nationally and notably in the local community of Bremerton, Kitsap County and Washington State, where the NCMS West Coast office is located. Also through its network, NCMS was able to nominate key personnel for PCNS to engage to carry forward the startup of the new business and the advanced composites curriculum development and training program at Olympic College.

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Profiles Composites North America Launches Advanced Composites Training Program

With a $100,000 WIA grant from Governor Gregoire, PCNA has partnered with Olympic College for a program to put veterans to work in advanced composites manufacturing.

With a focus on putting veterans to work, Profile Composites North America (PCNA) has embarked on an innovative strategy to develop advanced composites manufacturing in Kitsap County. The company is particularly committed to adapting the manufacturing process for those returning to civilian life with physical disabilities. The inaugural two-quarter, 30-credit certificate course conducted by PCNA began July 27th at Olympic College; and all but two are veterans. Concurrently, Profile Composites North America is in the process of selecting its initial work site and will choose its first manufacturing team from the class. The training and development program with Olympic College is consistent with the curriculum necessary for aerospace composite workers, allowing a broad opportunity for the participants within this growing industry.

“There has been an exceptionally strong and committed team to assist this in coming to fruition, especially through WorkSource Kitsap and Olympic College” said Geoff Wood, CEO of Profile Composites North America. “We also have a growing list of officials and organizations that are excited about what we’re doing and helping to make this successful. The National Center for Manufacturing Sciences (NCMS) and the Kitsap Economic Development Association (KEDA), in particular, were critical in helping us take the first steps. And the ongoing support of Governor Gregoire, Bremerton Mayor Lent, Congressman Dicks and Senator Murray have really helped pave the way for this effort.”

“WorkSource Kitsap – who is administering the grant, the Veterans’ Administration, and the Wounded Warriors program helped us put together our initial class of students, who are also potential employees,” Wood continued. “Clover Park Technical College and Peninsula College generously provided resources from their programs to get us started. And finally, Olympic College has been our training partner in this unique public-private collaboration that will be the foundation for the advanced composites industry in Kitsap County.”

This new company is an independent, not-for-profit spinoff of British Columbia-based Profile Composites (www.profilecomposites.com), a successful research, development, and manufacturing organization that has won the industry’s top international awards for innovation in advanced composites development projects. PCNA’s first products will focus on assistive devices, such as high-tech sport crutches that are of special interest in the disabled community and expects to diversify its manufacturing operations to serve aerospace and other markets. The company’s goals include the development of “adaptive manufacturing cells” for accommodation of various levels of worker abilities, which can be replicated in any advanced composites manufacturing setting.

Profile Composites North America is a non-profit corporation with a pending 501(c)3 status. Founded in January, 2011, the company’s mission is to develop a thriving advanced composites industry in Kitsap County, with a focus on veterans helping veterans.

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Specifically Doyle will help manage its Science, Technology, Engineering, and Mathematics (STEM) program focused on Remotely Operated Vehicles (ROV), and bring his unique perspective to students from his years serving on submarines in the U.S Navy, his extensive computer software development knowledge and his work with NCMS to help companies improve technology for the Department of Defense.

On Friday May 20 Doyle helped mentor students from North Kitsap High School and district middle schools as they participated in a variety of challenges to test the ROVs they spent several weeks designing and building in their classrooms. The pool event is the last step in the ROV program, where students put their hard work and skills to the test for the first time.

NCMS is working with the Navy to help increase the number of robotics-specific degreed engineers and technicians for future development and deployment of robotic and unmanned systems which are integral to ensuring the safety of the warfighter. This program will inspire the next generation of scientists and engineers by engaging students, kindergarten through college, in STEM-related hands-on learning activities using Navy content, preparing them for future employment in ROV disciplines, supporting academic institutions or the naval contractor community. Finally, it will help employ, retain and develop naval STEM professionals to support this technologically advanced sector.

Full Article, Not your typical tub toy, Kitsap Sun

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NCMS Partners with Navy to promote Science, Technology, Engineering and Mathematics (STEM) through remotely operated vehicle challenges

ANN ARBOR, MI – May 18, 2011. The National Center for Manufacturing Sciences (NCMS) today announced that it has received an award from the Naval Undersea Warfare Center (NUWC) Division Keyport to manage its Science, Technology, Engineering, and Mathematics (STEM) program focused on Remotely Operated Vehicles (ROV) in their local area. The cooperative agreement between NCMS and NUWC Keyport will support the Department of Defense’s (DoD) mission of scientific outreach and education in working to nurture future scientists capable of providing support to the development of DoD identified critical technologies.

The current lack of robotics-specific degreed engineers and technicians poses a serious threat to future development and deployment of robotic and unmanned systems which are integral to ensuring the safety of the warfighter. This program will inspire the next generation of scientists and engineers by engaging students, kindergarten through college, in STEM-related hands-on learning activities using Navy content, preparing them for future employment in ROV disciplines, supporting academic institutions or the naval contractor community. Finally, it will help employ, retain and develop naval STEM professionals to support this technologically advanced sector.

NCMS will leverage its experience in workforce training and interactive games-based learning to ensure that an educated and well-prepared ROV workforce is available to meet both naval and national competitiveness needs.

“The future of manufacturing depends on our ability to motivate and inspire students,” said NCMS President & CEO Rick Jarman. “Our experience in workforce training and technology will provide the DoD with the vision, tools, and skilled workforce to ensure a strong defense and keep the U.S. a global leader in advanced manufacturing.”

NCMS recently supported National Robotics Week by hosting Michigan Robotics Day at its Ann Arbor Headquarters. The event included demonstrations of robotic technology created by university and high school students, as well as opportunities for students to learn about the future of robotics from DoD and industry leaders while observing cutting edge robotics technology in action. The event was webcast to schools nationwide, maximizing the opportunities for student and industry participation.

Contact:
Phil Callihan philc@ncms.org o-(734) 995-2046 c-(734) 260-3724

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NCMS Senior Program Manager Doyle Maleche

NCMS Senior Program Managers Michael Fancher and Doyle Maleche joined a team of prestigious judges participating in the University of Washington Environmental Innovation Challenge. University of Washington students are creating next-generation clean technology solutions for everyday living. Seventeen student teams from around the state pitched and demonstrated their innovations at the UW Environmental Innovation Challenge Thursday, addressing today’s energy problems with novel solutions. Now in its third year, the Challenge focuses on the development of prototypes that solve environmental problems AND have market impact.

NCMS Senior Program Manager Michael Fancher

The event, produced by the Center for Innovation and Entrepreneurship in collaboration with Foster School of Business, College of Engineering, College of the Environment, and the UW Center for Commercialization, welcomed student teams representing the University of Washington, Seattle Pacific University, Washington State University, Western Washington University, University of British Columbia, University of Utah, Shoreline Community College, and Lake Washington Technical College. Their ideas ranged from designing and building airships and complex carbon fiber components for vehicles, to low-cost solutions for water purification and power generation in underdeveloped regions, methods for significantly increasing efficiency and market growth of alternative energy technologies, and a wind power generator that creates electricity through the movement of a pair of wings. The students came from business, engineering, environment, forest resources, built environment, public policy, and arts and sciences, and they all share a commitment to developing the innovations needed to accelerate the clean-tech economy.

Links to this and other Innovative Challenges

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Dana Ellis, Project Manager for “Environmentally Friendly Hot Cutting Solutions,” assists in the assembly of a fixture which will be used for evaluation of opacity generated by a variety of hot cutting techniques, at partner facility Edison Welding Institute.

Work has begun to develop new methods to reduce emissions during the breakup and recycling of the nuclear aircraft carrier USS Enterprise in 2016. The Enterprise is 89,600 tons full load; 1101 feet long, has a flight deck 252 feet wide, and a 133 foot beam. It is so big it dwarfs the largest drydock in Puget Sound Naval Shipyard, which is the Navy’s only organic site for breaking ships. If current oxy-fuel cutting methods alone are used to break it, environmental issues are certain to prolong the breaking process.

Oxy-Fuel cutting is currently the most commonly used method for large scale metal cutting and preparation operations, e.g. ship breaking. While this method is both cost effective and efficient it also creates large quantities of visible emissions, metal fumes and debris. This has led to compliance issues with air pollution and clean water requirements. Known alternative methods available at this time are nowhere near as efficient.

Test cut using MagneGas- a green natural gas for metal cutting

Safely dismantling and recycling any large ship poses a unique environmental challenge but special care must be taken when working on a nuclear powered vessel.

NCMS has formed a collaborative team to develop a new solution for the US Navy to use on these large ship breaking projects.

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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.

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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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NCMS West recently recognized its two most recent interns, Chris Stone and Victoria Walker, with Certificates of Appreciation signed by NCMS CEO and President Richard Jarman.

Stone, who assisted in research and technical document preparation for the Noble Peak Camera Evaluation, interned with NCMS staff from January-April 2010.  He is now employed in Radiological Controls, Puget Sound Naval Shipyard & Intermediate Maintenance Facility.  

Walker’s internship, January-February 2010, was part of her participation in the Olympic College “Running Start” program.  She graduates from Klahowya Secondary School in June 2010, and will begin studies as a Sophomore at Central Washington University in the fall.  Pictured with Hottinger and Walker is Teresa McDermott, Olympic College Director for Work Training and Work Integration and Learning.

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Bremerton Mayor Patty Lent recently paid a visit to the NCMS West  office in Washington State.  Photo (left to right) NCMS staff Michael Fancher, Jeff Walker, Mayor Lent, Doyle Maleche, Heidi Hottinger, Bremerton City Council Member Roy Runyon, Dana Ellis. Wes Lueders.

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Chris Stone is a Mechanical Engineering Technology student at Old Dominion University’s Bremerton campus where he successfully designed; built, programmed an advanced computer controlled underwater Remotely Operated Vehicle (ROV) capable of undersea exploration and survey for his senior design project.

Chris has a diverse background including a previous degree in Geography with a minor in Geology. He has worked in the ocean survey industry including participating in the completion of several large telecom cable project surveys.  He holds a private pilot license and plans to pursue a career in engineering working with the government sector.  

While in the internship program at NCMS, Chris is working to achieve a better understanding of engineering technologies and their role in providing solutions to government and commercial agency challenges.

Victoria Walker is a senior at Klahowya High School and also attends Olympic College part time where she made the Dean’s List.  When not in school or interning, she performs with the Klahowya Eagles Marching Band and Pep Band, holding the prestigious position of Flute Section Leader.  She has also earned awards for outstanding achievement in Math, Science, English, History, and Band and recently received the award for being the Most Inspirational Student in Band along with the Rotary Youth Leadership Award. 

Her goal is to work with the staff at NCMS to acquire first-hand learning experience of industry.

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